Methods of operating surgical end effectors

ABSTRACT

Methods for operating a surgical end effector that includes first and second jaws that are pivotally coupled together and are selectively movable between a fully open position and fully closed position. At least one method includes moving a dynamic clamping assembly through a closure stroke to apply a closure motion to the first and second jaws to move the first and second jaws from the fully open position to the fully closed position. A method also includes moving the dynamic clamping assembly through a firing stroke to perform a surgical function until the dynamic clamping assembly reaches an ending position within the closed first and second jaws. A method also includes moving the dynamic clamping assembly in direction configured to contact at least one positive jaw opening feature on at least one of the first and second jaws with to move the first and second jaws to the fully open position.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a perspective view of an electromechanical surgical system;

FIG. 2 is a perspective view of a distal end of an electromechanicalsurgical instrument portion of the surgical system of FIG. 1;

FIG. 3 is an exploded assembly view of an outer shell feature and theelectromechanical surgical instrument of FIG. 2;

FIG. 4 is a rear perspective view of a portion of the electromechanicalsurgical instrument of FIG. 2;

FIG. 5 is a partial exploded assembly view of a portion of an adapterand the electromechanical surgical instrument of the surgical system ofFIG. 1;

FIG. 6 is an exploded assembly view of a portion of the adapter of FIG.5;

FIG. 7 is a cross-sectional perspective view of a portion of anarticulation assembly of an adapter;

FIG. 8 is a perspective view of the articulation assembly of FIG. 7;

FIG. 9 is another perspective view of the articulation assembly of FIG.8;

FIG. 10 is an exploded assembly view of a loading unit employed in theelectromechanical surgical system of FIG. 1;

FIG. 11 is a perspective view of an alternative adapter embodiment;

FIG. 12 is a side elevational view of a portion of a loading unit of theadapter of FIG. 11 with the jaws thereof in an open position;

FIG. 13 is another side elevational view of a portion of the loadingunit of FIG. 11 with portions thereof shown in cross-section and thejaws thereof in a closed position;

FIG. 14 is a bottom view of a portion of the loading unit of FIG. 13with portions thereof shown in cross-section;

FIG. 15 is a perspective view of a portion of the loading unit of FIG.14 with a portion of the outer tube shown in phantom lines;

FIG. 16 is a cross-sectional view of a proximal portion of anotheradapter employing various seal arrangements therein;

FIG. 17 is an end cross-sectional view of a portion of the adapter ofFIG. 16;

FIG. 18 is a side elevation al view of another adapter;

FIG. 19 is a cross-sectional view of a portion of the adapter of FIG.18;

FIG. 20 is a rear perspective view of portions of another adapter;

FIG. 21 is a cross-sectional view of another adapter;

FIG. 22 is a perspective view of a portion of another loading unit of anadapter with the jaws thereof in a closed position;

FIG. 23 is a side elevational view of the loading unit of FIG. 22;

FIG. 24 is a perspective view of the loading unit of FIG. 23 after thedynamic clamping assembly has initially contacted positive channelopening features on a channel of the dynamic loading unit;

FIG. 25 is a side elevational view of the loading unit of FIG. 24;

FIG. 26 is another side elevational view of the loading unit of FIGS.22-25 with the jaws thereof in a fully open position;

FIG. 27 is a side elevational view of a portion of another loading unitof an adapter with the jaws thereof in a fully closed position;

FIG. 28 is another side elevational view of the loading unit of FIG. 27with the jaws thereof in a partially open position;

FIG. 29 is another side elevational view of the loading unit of FIGS. 27and 28 with the jaws thereof in a fully open position;

FIG. 30 is a side elevational view of a portion of another loading unitof an adapter with the jaws thereof in a fully open position;

FIG. 31 is another side elevational view of the loading unit of FIG. 30,with the jaws thereof in a partially closed position;

FIG. 32 is another side elevational view of the loading unit of FIGS. 30and 31, with the jaws thereof in a closed position prior to initiationof a firing stroke;

FIG. 33 is a side elevational view of a portion of another loading unitof an adapter with the jaws thereof in a fully open position;

FIG. 34 is a side elevational view of a portion of another loading unitof an adapter with the jaws thereof in a fully open position;

FIG. 35 is a cross-sectional elevational view of a dynamic clampingassembly embodiment;

FIG. 36 is an end elevational view of a portion of the dynamic clampingassembly of FIG. 35 interacting with an anvil assembly of a loading unitof an adapter shown in cross-section;

FIG. 37 is a cross-sectional view of a body portion of the dynamicclamping assembly of FIG. 36 taken along line 37-37 in FIG. 36;

FIG. 38 is a side elevational view of another dynamic clamping assemblywith a portion thereof shown in cross-section;

FIG. 39 is a cross-sectional view of a portion of the dynamic clampingassembly of FIG. 38 taken along line 39-39 in FIG. 38;

FIG. 40 is an exploded perspective assembly view of portions of anarticulation locking system embodiment of an adapter;

FIG. 41 is a partial cross-sectional perspective view of a portion of anadapter and the articulation locking system of FIG. 40;

FIG. 42 is a partial top cross-sectional view of the articulationlocking system of FIGS. 40 and 41 in an unlocked position;

FIG. 43 is another partial top cross-sectional view of the articulationlocking system of FIGS. 40-42 in a locked position;

FIG. 44 is a partial cross-sectional view of a portion of a driveassembly locking system of an adapter in an unlocked position;

FIG. 45 is a partial cross-sectional view of the drive assembly lockingsystem of FIG. 44 with an unfired cartridge loaded in an end effectorand the drive assembly locking system in an unlocked position;

FIG. 46 is another partial cross-sectional view of the drive assemblylocking system of FIGS. 44 and 45 with an unfired cartridge loaded inthe end effector and the drive assembly locking system in an unlockedposition and a dynamic clamping assembly thereof starting to movethrough a closing stroke;

FIG. 47 is another partial cross-sectional view of the drive assemblylocking system of FIGS. 44-46 with an unfired cartridge loaded in theend effector and the drive assembly locking system in a firing positionready to start moving through a firing stroke;

FIG. 48 is another partial cross-sectional view of the drive assemblylocking system of FIGS. 44-47 after the dynamic clamping assembly hasbeen distally advanced through the firing stroke;

FIG. 49 is another partial cross-sectional view of the drive assemblylocking system of FIGS. 44-48 as the dynamic clamping assembly is beingretracted but before resuming a starting position;

FIG. 50 is another partial cross-sectional view of the drive assemblylocking system of FIGS. 44-48 after the dynamic clamping assembly hasbeen retracted back to the starting position and the drive assemblylocking system is in the locked position;

FIG. 51 is a side view of the end effector of FIGS. 44-50 with thedynamic clamping assembly shown in a starting position and the jawsthereof in a fully open position;

FIG. 52 shows the position of a drive lock member of the drive assemblylocking system of FIGS. 44-50 in a locked position around the dynamicclamping assembly when in the starting position;

FIG. 53 is a side view of the end effector of FIG. 51 after the dynamicclamping assembly has completed a closure stroke and is in a firingposition;

FIG. 54 shows the position of a drive lock member of the drive assemblylocking system of FIGS. 44-50 in a locked position around the dynamicclamping assembly in the firing position;

FIG. 55 is a side view of a dynamic clamping assembly and a pivotinglock member of another drive assembly locking system in a lockedposition prior to installing an unspent cartridge into an end effectorof an adapter;

FIG. 56 is another side view of the drive assembly locking system ofFIG. 55 with an unspent cartridge supported in position to move thepivoting lock member into an unlocked position;

FIG. 57 is an exploded view of the pivoting lock member and cartridgeshown in FIG. 56;

FIG. 58 is a perspective view of another cartridge embodiment;

FIG. 59 is a top perspective view of another loading unit of an adapterwith the jaws thereof in a closed position and a dynamic clampingassembly positioned in a firing position;

FIG. 60 is a bottom perspective view of the loading unit of FIG. 59;

FIG. 61 is a side elevational view of the loading unit of FIG. 59 withthe jaws in the closed position;

FIG. 62 is another side elevational view of the loading unit of FIG. 61with the dynamic clamping assembly positioned in a firing position;

FIG. 63 is another side elevational view of the loading unit of FIG. 62with the dynamic clamping assembly in a partially fired position;

FIG. 64 is another side elevational view of the loading unit of FIG. 63with the dynamic clamping assembly positioned in the ending position;

FIG. 65 is a partial side elevational view of another loading unitillustrating a dynamic clamping assembly thereof in a partially firedconfiguration;

FIG. 66 is a cross-sectional end view of a portion of an anvil assemblyof a loading unit;

FIG. 67 is a cross-sectional end view of a portion of another anvilassembly of a loading unit;

FIG. 68 is a top view of a loading unit of an adapter with the toolassembly thereof in an unarticulated position;

FIG. 69 is another top view of the loading unit of FIG. 68 with the toolassembly in a first articulated position;

FIG. 70 is another top view of the loading unit of FIGS. 68 and 69 withthe tool assembly in a second articulated position;

FIG. 71 is a perspective view of a portion of an adapter;

FIG. 72 is a perspective view of another portion of an adapter;

FIG. 73 is a partial cross-sectional perspective view of an articulationsystem and sensor assembly embodiment of an adapter in an unarticulated(neutral) position;

FIG. 74 is another perspective view of the articulation system andsensor assembly of FIG. 73 in a first articulated position;

FIG. 75 is another perspective view of the articulation system andsensor assembly of FIGS. 73 and 74 in a second articulated position;

FIG. 76 is a partial cross-sectional view a portion of an alternativeproximal drive shaft and bearing housing of an alternative articulationsystem in an unarticulated (neutral) position;

FIG. 77 is another partial cross-sectional view the portion of analternative proximal drive shaft and bearing housing of the alternativearticulation system of FIG. 76 in an articulated position;

FIG. 78 is a partial cross-sectional view a portion of an alternativeproximal drive shaft and bearing housing of an alternative articulationsystem in an unarticulated (neutral) position;

FIG. 79 is another partial cross-sectional view the portion of analternative proximal drive shaft and bearing housing of the alternativearticulation system of FIG. 78 in an articulated position;

FIG. 80 is a partial cross-sectional perspective view of anotherarticulation system and sensor assembly embodiment of an adapter in anunarticulated (neutral) position;

FIG. 81 is a partial cross-sectional side view of the articulationsystem and sensor assembly embodiment of an adapter of FIG. 80 in theunarticulated (neutral) position;

FIG. 82 is another partial cross-sectional side view of the articulationsystem and sensor assembly embodiment of an adapter of FIGS. 80 and 81in an articulated position;

FIG. 83 is another partial cross-sectional side view of the articulationsystem and sensor assembly embodiment of an adapter of FIGS. 80-82 inanother articulated position;

FIG. 84 is a perspective view of portions of an articulation system andsensor system and a shaft rotation system and sensor arrangement ofanother adapter;

FIG. 85 is a partial cross-sectional view of a loading unit toolassembly of another adapter with the jaws thereof in a fully openposition;

FIG. 86 is another a partial cross-sectional view of the loading unittool assembly of FIG. 85 with the jaws thereof in a closed position;

FIG. 87 is another a partial cross-sectional view of the loading unittool assembly of FIGS. 85 and 86 with a dynamic clamping assemblythereof at the end of a closing stroke and the jaws thereof in a fullyclosed position;

FIG. 88 is another partial cross-sectional view of the loading unit toolassembly of FIGS. 85-87 with the dynamic clamping assembly thereofapproaching the end of a firing stroke;

FIG. 89 is a side elevational view of a tool assembly of an adapter withthe dynamic clamping assembly in a starting position and the jawsotherwise shown in a closed position for clarity;

FIG. 90 is a partial perspective and cross-sectional view of a firingsystem sensor assembly or system of an adapter;

FIG. 91 is a partial side cross-sectional view of the firing systemsensor assembly of FIG. 90 in a starting position;

FIG. 92 is another partial side cross-sectional view of the firingsystem sensor assembly of FIGS. 90 and 91 after the firing system hascompleted a closure stroke and prior to starting a firing stroke;

FIG. 93 is another partial side cross-sectional view of the firingsystem sensor assembly of FIGS. 90-92 after the firing system hascompleted the firing stroke;

FIG. 94 is a diagrammatical depiction of portions of the firing systemsensor assembly of FIGS. 90-93 as the firing system is moved from astarting position to an ending position;

FIG. 95 is a graphical depiction of a displacement measured by thefiring system sensor assembly of FIGS. 90-93 based upon the firingstroke distance of a dynamic clamping assembly;

FIG. 96 is a perspective view of portions of an adapter that includes anarrangement for measuring an amount of strain experienced by anarticulation driver of the adapter;

FIG. 97 is a flow chart depicting a method of controlling motors of anelectromechanical surgical device attached to an adapter of FIG. 96;

FIG. 98 is an exploded assembly perspective view of a motor controlsystem of an electromechanical surgical device for controlling themotors thereof;

FIG. 99 is a perspective view of another motor control system of anelectromechanical surgical device for controlling the motors thereof;

FIG. 100 is an exploded side view of the motor control system of FIG.99; and

FIG. 101 is a partial end view of a portion of the motor control systemassociated with one of the motors of an electromechanical surgicalinstrument;

FIG. 102 is a schematic diagram of a circuit for controlling a motor ofa surgical instrument;

FIG. 103 is a schematic diagram of a circuit for controlling a motor ofa surgical instrument;

FIG. 104 is a schematic diagram of a position sensor of a surgicalinstrument;

FIG. 105 is a logic flow diagram of a process for monitoring a motorcurrent of a surgical instrument;

FIG. 106 is a pair of graphs of various clamping member strokes executedper the logic depicted in FIG. 105;

FIG. 107 is a pair of graphs of various clamping member strokes executedper the logic depicted in FIG. 105;

FIG. 108 is a diagram of an end effector including a gap sensor and acartridge identity sensor;

FIG. 109 is a schematic diagram of a Hall effect sensor;

FIG. 110 is a cutaway view of the end effector partially joined to thedistal end of the adapter;

FIG. 111 is a sectional of the end effector joined to the distal end ofthe adapter along the longitudinal axis thereof;

FIG. 112 is a logic flow diagram of a process for selecting an initialspeed at which to fire the clamping member;

FIG. 113 is a graph of various clamping member strokes executed per thelogic illustrated in FIG. 112;

FIG. 114 is a logic flow diagram of a process for controlling a speed ofa clamping member during a firing stroke;

FIG. 115 is a logic flow diagram of a process for detecting a definedposition according to motor current;

FIG. 116 is a graph of various clamping member firing strokes executedper the logic depicted in FIGS. 114 and 115;

FIG. 117 is an exploded view of an anvil including a slot stop member;

FIG. 118 is a partial cutaway view of an anvil including a slot stopmember;

FIG. 119 is a sectional view of an anvil including a slot stop member;

FIG. 120 illustrates a side elevational view of an anvil including aslot stop member, according to one aspect of the present disclosure.

FIG. 121 is a longitudinal sectional view of an end effector and a driveassembly including a stop member;

FIG. 122 is a longitudinal sectional view of an end effector and a driveassembly including a stop member;

FIG. 123 is a longitudinal sectional view of an end effector including astop member located distally in the elongated slot; and

FIG. 124 is a longitudinal sectional view of an end effector including astop member located distally in the elongated slot.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. PatentApplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. ______, entitled SEALED ADAPTERS    FOR USE WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney Docket    No. END8286USNP/170227;-   U.S. patent application Ser. No. ______, entitled END EFFECTORS WITH    POSITIVE JAW OPENING FEATURES FOR USE WITH ADAPTERS FOR    ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney Docket No.    END8277USNP/170219;-   U.S. patent application Ser. No. ______, entitled SURGICAL END    EFFECTORS WITH CLAMPING ASSEMBLIES CONFIGURED TO INCREASE JAW    APERTURE RANGES; Attorney Docket No. END8278USNP/170220;-   U.S. patent application Ser. No. ______, entitled SURGICAL END    EFFECTORS WITH PIVOTAL JAWS CONFIGURED TO TOUCH AT THEIR RESPECTIVE    DISTAL ENDS WHEN FULLY CLOSED; Attorney Docket No.    END8283USNP/170223;-   U.S. patent application Ser. No. ______, entitled SURGICAL END    EFFECTORS WITH JAW STIFFENER ARRANGEMENTS CONFIGURED TO PERMIT    MONITORING OF FIRING MEMBER; Attorney Docket No. END8282USNP/170221;-   U.S. patent application Ser. No. ______, entitled ADAPTERS WITH END    EFFECTOR POSITION SENSING AND CONTROL ARRANGEMENTS FOR USE IN    CONNECTION WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney    Docket No. END8281USNP/170228;-   U.S. patent application Ser. No. ______, entitled DYNAMIC CLAMPING    ASSEMBLIES WITH IMPROVED WEAR CHARACTERISTICS FOR USE IN CONNECTION    WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney Docket No.    END8279USNP/170222;-   U.S. patent application Ser. No. ______, entitled ADAPTERS WITH    FIRING STROKE SENSING ARRANGEMENTS FOR USE IN CONNECTION WITH    ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney Docket No.    END8287USNP/170229;-   U.S. patent application Ser. No. ______, entitled ADAPTERS WITH    CONTROL SYSTEMS FOR CONTROLLING MULTIPLE MOTORS OF AN    ELECTROMECHANICAL SURGICAL INSTRUMENT; Attorney Docket No.    END8284USNP/170224;-   U.S. patent application Ser. No. ______, entitled HANDHELD    ELECTROMECHANICAL SURGICAL INSTRUMENTS WITH IMPROVED MOTOR CONTROL    ARRANGEMENTS FOR POSITIONING COMPONENTS OF AN ADAPTER COUPLED    THERETO; Attorney Docket No. END8285USNP/170225;-   U.S. patent application Ser. No. ______, entitled SYSTEMS AND    METHODS OF CONTROLLING A CLAMPING MEMBER FIRING RATE OF A SURGICAL    INSTRUMENT; Attorney Docket No. END8280USNP/170226; and-   U.S. patent application Ser. No. ______, entitled SYSTEMS AND    METHODS OF CONTROLLING A CLAMPING MEMBER; Attorney Docket No.    END8335USNP/170231;

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIG. 1 depicts a motor-driven (electromechanical) surgical system 1 thatmay be used to perform a variety of different surgical procedures. Ascan be seen in that Figure, one example of the surgical system 1includes a powered handheld electromechanical surgical instrument 100that is configured for selective attachment thereto of a plurality ofdifferent surgical tool implements (referred to herein as “adapters”)that are each configured for actuation and manipulation by the poweredhandheld electromechanical surgical instrument. As illustrated in FIG.1, the handheld surgical instrument 100 is configured for selectiveconnection with an adapter 200, and, in turn, adapter 200 is configuredfor selective connection with end effectors that comprise a single useloading unit (“SULU”) or a disposable loading unit (“DLU”) or a multipleuse loading unit (“MULU”). In another surgical system embodiment,various forms of adapter 200 may also be effectively employed with atool drive assembly of a robotically controlled or automated surgicalsystem. For example, the surgical tool assemblies disclosed herein maybe employed with various robotic systems, instruments, components andmethods such as, but not limited to, those disclosed in U.S. Pat. No.9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, which is hereby incorporated by referenceherein in its entirety.

As illustrated in FIGS. 1 and 2, surgical instrument 100 includes apower-pack 101 and an outer shell housing 10 that is configured toselectively receive and substantially encase the power-pack 101. Thepower pack 101 may also be referred to herein as handle assembly 101.One form of surgical instrument 100, for example, is disclosed inInternational Publication No. WO 2016/057225 A1, InternationalApplication No. PCT/US2015/051837, entitled HANDHELD ELECTROMECHANICALSURGICAL SYSTEM, the entire disclosure of which is hereby incorporatedby reference herein. Various features of surgical instrument 100 willnot be disclosed herein beyond what is necessary to understand thevarious features of the inventions disclosed herein with it beingunderstood that further details may be gleaned from reference to WO2016/057225 A1 and other references incorporated by reference herein.

As illustrated in FIG. 3, outer shell housing 10 includes a distalhalf-section 10 a and a proximal half-section 10 b that is pivotablyconnected to distal half-section 10 a by a hinge 16 located along anupper edge of distal half-section 10 a and proximal half-section 10 b.When joined, distal and proximal half-sections 10 a, 10 b define a shellcavity 10 c therein in which the power-pack 101 is selectively situated.Each of distal and proximal half-sections 10 a, 10 b includes arespective upper shell portion 12 a, 12 b, and a respective lower shellportion 14 a, 14 b. Lower shell portions 14 a, 14 b define a snapclosure feature 18 for selectively securing the lower shell portions 14a, 14 b to one another and for maintaining shell housing 10 in a closedcondition. Distal half-section 10 a of shell housing 10 defines aconnecting portion 20 that is configured to accept a corresponding drivecoupling assembly 210 of adapter 200 (see FIG. 5). Specifically, distalhalf-section 10 a of shell housing 10 has a recess that receives aportion of drive coupling assembly 210 of adapter 200 when adapter 200is mated to surgical instrument 100.

Connecting portion 20 of distal half-section 10 a defines a pair ofaxially extending guide rails 21 a, 21 b that project radially inwardfrom inner side surfaces thereof as shown in FIG. 5. Guide rails 21 a,21 b assist in rotationally orienting adapter 200 relative to surgicalinstrument 100 when adapter 200 is mated to surgical instrument 100.Connecting portion 20 of distal half-section 10 a defines threeapertures 22 a, 22 b, 22 c that are formed in a distally facing surfacethereof and which are arranged in a common plane or line with oneanother. Connecting portion 20 of distal half-section 10 a also definesan elongate slot 24 also formed in the distally facing surface thereof.Connecting portion 20 of distal half-section 10 a further defines afemale connecting feature 26 (see FIG. 2) formed in a surface thereof.Female connecting feature 26 selectively engages with a male connectingfeature of adapter 200.

Distal half-section 10 a of shell housing 10 supports a distal facingtoggle control button 30. The toggle control button 30 is capable ofbeing actuated in a left, right, up and down direction upon applicationof a corresponding force thereto or a depressive force thereto. Distalhalf-section 10 a of shell housing 10 supports a right-side pair ofcontrol buttons 32 a, 32 b (see FIG. 3); and a left-side pair of controlbutton 34 a, 34 b (see FIG. 2). The right-side control buttons 32 a, 32b and the left-side control buttons 34 a, 34 b are capable of beingactuated upon application of a corresponding force thereto or adepressive force thereto. Proximal half-section 10 b of shell housing 10supports a right-side control button 36 a (see FIG. 3) and a left-sidecontrol button 36 b (see FIG. 2). Right-side control button 36 a andleft-side control button 36 b are capable of being actuated uponapplication of a corresponding force thereto or a depressive forcethereto.

Shell housing 10 includes a sterile barrier plate assembly 60selectively supported in distal half-section 10 a. Specifically, thesterile barrier plate assembly 60 is disposed behind connecting portion20 of distal half-section 10 a and within shell cavity 10 c of shellhousing 10. The plate assembly 60 includes a plate 62 rotatablysupporting three coupling shafts 64 a, 64 b, 64 c (see FIGS. 3 and 5).Each coupling shaft 64 a, 64 b, 64 c extends from opposed sides of plate62 and has a tri-lobe transverse cross-sectional profile. Each couplingshaft 64 a, 64 b, 64 c extends through the respective apertures 22 a, 22b, 22 c of connecting portion 20 of distal half-section 10 a when thesterile barrier plate assembly 60 is disposed within shell cavity 10 cof shell housing 10. The plate assembly 60 further includes anelectrical pass-through connector 66 supported on plate 62. Pass-throughconnector 66 extends from opposed sides of plate 62. Pass-throughconnector 66 defines a plurality of contact paths each including anelectrical conduit for extending an electrical connection across plate62. When the plate assembly 60 is disposed within shell cavity 10 c ofshell housing 10, distal ends of coupling shaft 64 a, 64 b, 64 c and adistal end of pass-through connector 66 are disposed or situated withinconnecting portion 20 of distal half-section 10 a of shell housing 10,and are configured to electrically and/or mechanically engage respectivecorresponding features of adapter 200.

Referring to FIGS. 3 and 4, the power-pack or the handle assembly 101includes an inner handle housing 110 having a lower housing portion 104and an upper housing portion 108 extending from and/or supported onlower housing portion 104. Lower housing portion 104 and upper housingportion 108 are separated into a distal half section 110 a and aproximal half-section 110 b connectable to distal half-section 110 a bya plurality of fasteners. When joined, distal and proximal half-sections110 a, 110 b define the inner handle housing 110 having an inner housingcavity 110 c therein in which a power-pack core assembly 106 issituated. Power-pack core assembly 106 is configured to control thevarious operations of surgical instrument 100.

Distal half-section 110 a of inner handle housing 110 supports a distaltoggle control interface 130 that is in operative registration with thedistal toggle control button 30 of shell housing 10. In use, when thepower-pack 101 is disposed within shell housing 10, actuation of thetoggle control button 30 exerts a force on toggle control interface 130.Distal half-section 110 a of inner handle housing 110 also supports aright-side pair of control interfaces (not shown), and a left-side pairof control interfaces 132 a, 132 b. In use, when the power-pack 101 isdisposed within shell housing 10, actuation of one of the right-sidepair of control buttons or the left-side pair of control button ofdistal half-section 10 a of shell housing 10 exerts a force on arespective one of the right-side pair of control interfaces 132 a, 132 bor the left-side pair of control interfaces 132 a, 132 b of distalhalf-section 110 a of inner handle housing 110.

With reference to FIGS. 1-5, inner handle housing 110 provides a housingin which power-pack core assembly 106 is situated. Power-pack coreassembly 106 includes a battery circuit 140, a controller circuit board142 and a rechargeable battery 144 configured to supply power to any ofthe electrical components of surgical instrument 100. Controller circuitboard 142 includes a motor controller circuit board 142 a, a maincontroller circuit board 142 b, and a first ribbon cable 142 cinterconnecting motor controller circuit board 142 a and main controllercircuit board 142 b. Power-pack core assembly 106 further includes adisplay screen 146 supported on main controller circuit board 142 b.Display screen 146 is visible through a clear or transparent window 110d (see FIG. 3) provided in proximal half-section 110 b of inner handlehousing 110. It is contemplated that at least a portion of inner handlehousing 110 may be fabricated from a transparent rigid plastic or thelike. It is further contemplated that shell housing 10 may eitherinclude a window formed therein (in visual registration with displayscreen 146 and with window 110 d of proximal half-section 110 b of innerhandle housing 110, and/or shell housing 10 may be fabricated from atransparent rigid plastic or the like.

Power-pack core assembly 106 further includes a first motor 152, asecond motor 154, and a third motor 156 that are supported by motorbracket 148 and are each electrically connected to controller circuitboard 142 and battery 144. Motors 152, 154, 156 are disposed betweenmotor controller circuit board 142 a and main controller circuit board142 b. Each motor 152, 154, 156 includes a respective motor shaft 152 a,154 a, 156 a extending therefrom. Each motor shaft 152 a, 154 a, 156 ahas a tri-lobe transverse cross-sectional profile for transmittingrotative forces or torque. Each motor 152, 154, 156 is controlled by arespective motor controller. Rotation of motor shafts 152 a, 154 a, 156a by respective motors 152, 154, 156 function to drive shafts and/orgear components of adapter 200 in order to perform the variousoperations of surgical instrument 100. In particular, motors 152, 154,156 of power-pack core assembly 106 are configured to drive shaftsand/or gear components of adapter 200.

As illustrated in FIGS. 1 and 5, surgical instrument 100 is configuredfor selective connection with adapter 200, and, in turn, adapter 200 isconfigured for selective connection with end effector 500. Adapter 200includes an outer knob housing 202 and an outer tube 206 that extendsfrom a distal end of knob housing 202. Knob housing 202 and outer tube206 are configured and dimensioned to house the components of adapterassembly 200. Outer tube 206 is dimensioned for endoscopic insertion, inparticular, that outer tube is passable through a typical trocar port,cannula or the like. Knob housing 202 is dimensioned to not enter thetrocar port, cannula of the like. Knob housing 202 is configured andadapted to connect to connecting portion 20 of the outer shell housing10 of surgical instrument 100.

Adapter 200 is configured to convert a rotation of either of first orsecond coupling shafts 64 a, 64 b of surgical instrument 100 into axialtranslation useful for operating a drive assembly 540 and anarticulation link 560 of end effector 500, as illustrated in FIG. 10 andas will be described in greater detail below. As illustrated in FIG. 6,adapter 200 includes the proximal inner housing assembly 204 thatrotatably supports a first rotatable proximal drive shaft 212, a secondrotatable proximal drive shaft 214, and a third rotatable proximal driveshaft 216 therein. Each proximal drive shaft 212, 214, 216 functions asa rotation receiving member to receive rotational forces from respectivecoupling shafts 64 a, 64 b and 64 c of surgical instrument 100. Inaddition, the drive coupling assembly 210 of adapter 200 is alsoconfigured to rotatably support first, second and third connectorsleeves 218, 220 and 222, respectively, arranged in a common plane orline with one another. Each connector sleeve 218, 220, 222 is configuredto mate with respective first, second and third coupling shafts 64 a, 64b, 64 c of surgical instrument 100, as described above. Each connectorsleeves 218, 222, 220 is further configured to mate with a proximal endof respective first, second, and third proximal drive shafts 212, 214,216 of adapter 200.

Drive coupling assembly 210 of adapter 200 also includes a first, asecond, and a third biasing member 224, 226, and 228 disposed distallyof respective first, second, and third connector sleeves 218, 220, 222.Each biasing members 224, 226, and 228 is disposed about respectivefirst, second, and third rotatable proximal drive shaft 212, 214, and216. Biasing members 224, 226, and 228 act on respective connectorsleeves 218, 222, and 220 to help maintain connector sleeves 218, 222.and 220 engaged with the distal end of respective coupling shafts 64 a,64 b, and 64 c of surgical instrument 100 when adapter 200 is connectedto surgical instrument 100.

Also in the illustrated arrangement, adapter 200 includes first, second,and third drive converting assemblies 240, 250, 260, respectively, thatare each disposed within inner housing assembly 204 and outer tube 206.Each drive converting assembly 240, 250, 260 is configured and adaptedto transmit or convert a rotation of a first, second, and third couplingshafts 64 a, 64 b, and 64 c of surgical instrument 100 into axialtranslation of an articulation driver or bar 258 of adapter 200, toeffectuate articulation of end effector 500; a rotation of a ring gear266 of adapter 200, to effectuate rotation of adapter 200; or axialtranslation of a distal drive member 248 of adapter 200 to effectuateclosing, opening, and firing of end effector 500.

Still referring to FIG. 6, first force/rotation transmitting/convertingassembly 240 includes first rotatable proximal drive shaft 212, which,as described above, is rotatably supported within inner housing assembly204. First rotatable proximal drive shaft 212 includes a non-circular orshaped proximal end portion configured for connection with firstconnector sleeve 218 which is connected to respective first couplingshaft 64 a of surgical instrument 100. First rotatable proximal driveshaft 212 includes a threaded distal end portion 212 b. Firstforce/rotation transmitting/converting assembly 240 further includes adrive coupling nut 244 that threadably engages the threaded distal endportion 212 b of first rotatable proximal drive shaft 212, and which isslidably disposed within outer tube 206. Drive coupling nut 244 isslidably keyed within proximal core tube portion of outer tube 206 so asto be prevented from rotation as first rotatable proximal drive shaft212 is rotated. In this manner, as the first rotatable proximal driveshaft 212 is rotated, drive coupling nut 244 is translated alongthreaded distal end portion 212 b of first rotatable proximal driveshaft 212 and, in turn, through and/or along outer tube 206.

First force/rotation transmitting/converting assembly 240 furtherincludes a distal drive member 248 that is mechanically engaged withdrive coupling nut 244, such that axial movement of drive coupling nut244 results in a corresponding amount of axial movement of distal drivemember 248. The distal end portion of distal drive member 248 supports aconnection member 247 configured and dimensioned for selectiveengagement with an engagement member 546 of a drive assembly 540 of endeffector 500 (FIG. 10). Drive coupling nut 244 and/or distal drivemember 248 function as a force transmitting member to components of endeffector 500. In operation, as first rotatable proximal drive shaft 212is rotated, as a result of the rotation of first coupling shaft 64 a ofsurgical instrument 100, drive coupling nut 244 is translated axiallyalong first rotatable proximal drive shaft 212. As drive coupling nut244 is translated axially along first rotatable proximal drive shaft212, distal drive member 248 is translated axially relative to outertube 206. As distal drive member 248 is translated axially, withconnection member 247 connected thereto and engaged with a hollow drivemember 548 attached to drive assembly 540 of end effector 500 (FIG. 10),distal drive member 248 causes concomitant axial translation of driveassembly 540 of end effector 500 to effectuate a closure of a toolassembly portion 600 of the end effector 500 and a firing of variouscomponents within the tool assembly.

Still referring to FIG. 6, second drive converting assembly 250 ofadapter 200 includes second proximal drive shaft 214 that is rotatablysupported within inner housing assembly 204. Second rotatable proximaldrive shaft 214 includes a non-circular or shaped proximal end portionconfigured for connection with second coupling shaft 64 c of surgicalinstrument 100. Second rotatable proximal drive shaft 214 furtherincludes a threaded distal end portion 214 a configured to threadablyengage an articulation bearing housing 253 of an articulation bearingassembly 252. Referring to FIGS. 6-9, the articulation bearing housing253 supports an articulation bearing 255 that has an inner race 257 thatis independently rotatable relative to an outer race 259. Articulationbearing housing 253 has a non-circular outer profile, for exampletear-dropped shaped, that is slidably and non-rotatably disposed withina complementary bore (not shown) of inner housing hub 204 a. Seconddrive converting assembly 250 of adapter 200 further includesarticulation bar 258 that has a proximal portion that is secured toinner race 257 of articulation bearing 255. A distal portion ofarticulation bar 258 includes a slot 258 a therein, which is configuredto accept a hook 562 the articulation link 560 (FIG. 10) of end effector500. Articulation bar 258 functions as a force transmitting member tocomponents of end effector 500. In the illustrated arrangement and asfurther discussed in WO 2016/057225 A1, articulation bearing assembly252 is both rotatable and longitudinally translatable and is configuredto permit free, unimpeded rotational movement of end effector 500 whenits first and second jaw members 610, 700 are in an approximatedposition and/or when jaw members 610, 700 are articulated.

In operation, as second proximal drive shaft 214 is rotated, thearticulation bearing assembly 252 is axially translated along threadeddistal end portion 214 a of second proximal drive shaft 214, which inturn, causes articulation bar 258 to be axially translated relative toouter tube 206. As articulation bar 258 is translated axially,articulation bar 258, being coupled to articulation link 560 of endeffector 500, causes concomitant axial translation of articulation link560 of end effector 500 to effectuate an articulation of tool assembly600. Articulation bar 258 is secured to inner race 257 of articulationbearing 253 and is thus free to rotate about the longitudinal axisrelative to outer race 259 of articulation bearing 253.

As illustrated in FIG. 6, adapter 200 includes a third drive convertingassembly 260 that is supported in inner housing assembly 204. Thirddrive converting assembly 260 includes rotation ring gear 266 that isfixedly supported in and connected to outer knob housing 202. Ring gear266 defines an internal array of gear teeth 266 a and includes a pair ofdiametrically opposed, radially extending protrusions 266 b. Protrusions266 b are configured to be disposed within recesses defined in outerknob housing 202, such that rotation of ring gear 266 results inrotation of outer knob housing 202, and vice a versa. Third driveconverting assembly 260 further includes third rotatable proximal driveshaft 216 which, as described above, is rotatably supported within innerhousing assembly 204. Third rotatable proximal drive shaft 216 includesa non-circular or shaped proximal end portion that is configured forconnection with third connector 220. Third rotatable proximal driveshaft 216 includes a spur gear 216 keyed to a distal end thereof. Areversing spur gear 264 inter-engages spur gear 216 a of third rotatableproximal drive shaft 216 to gear teeth 266 a of ring gear 266. Inoperation, as third rotatable proximal drive shaft 216 is rotated, dueto a rotation of the third coupling shaft 64 b of surgical instrument100, spur gear 216 a of third rotatable proximal drive shaft 216 engagesreversing gear 264 causing reversing gear 264 to rotate. As reversinggear 264 rotates, ring gear 266 also rotates thereby causing outer knobhousing 202 to rotate. Rotation of the outer knob housing 202 causes theouter tube 206 to rotate about longitudinal axis of adapter 200. Asouter tube 206 is rotated, end effector 500 that is connected to adistal end portion of adapter 200, is also rotated about a longitudinalaxis of adapter 200.

Adapter 200 further includes an attachment/detachment button 272 (FIG.5) that is supported on a stem 273 (FIG. 6) that projects from drivecoupling assembly 210 of adapter 200. The attachment/detachment button272 is biased by a biasing member (not shown) that is disposed within oraround stem 273, to an un-actuated condition. Button 272 includes a lipor ledge that is configured to snap behind a corresponding lip or ledgeof connecting portion 20 of the surgical instrument 100. As alsodiscussed in WO 2016/057225 A1, the adapter 200 may further include alock mechanism 280 for fixing the axial position of distal drive member248. As can be seen in FIG. 21, for example, lock mechanism 280 includesa button 282 that is slidably supported on outer knob housing 202. Lockbutton 282 is connected to an actuation bar (not shown) that extendslongitudinally through outer tube 206. Actuation bar moves upon amovement of lock button 282. In operation, in order to lock the positionand/or orientation of distal drive member 248, a user moves lock button282 from a distal position to a proximal position, thereby causing thelock out (not shown) to move proximally such that a distal face of thelock out moves out of contact with camming member 288, which causescamming member 288 to cam into recess 249 of distal drive member 248. Inthis manner, distal drive member 248 is prevented from distal and/orproximal movement. When lock button 282 is moved from the proximalposition to the distal position, the distal end of actuation bar movesdistally into the lock out (not shown), against the bias of a biasingmember (not shown), to force camming member 288 out of recess 249,thereby allowing unimpeded axial translation and radial movement ofdistal drive member 248.

Returning again to FIG. 6, adapter 200 includes an electrical assembly290 supported on and in outer knob housing 202 and inner housingassembly 204. Electrical assembly 290 includes a plurality of electricalcontact blades 292, supported on a circuit board 294, for electricalconnection to pass-through connector of plate assembly of shell housing10 of surgical instrument 100. Electrical assembly 290 serves to allowfor calibration and communication information (i.e., life-cycleinformation, system information, force information) to pass to thecircuit board of surgical instrument 100 via an electrical receptacleportion of the power-pack core assembly 106 of surgical instrument 100.Electrical assembly 290 further includes a strain gauge 296 that iselectrically connected to circuit board 294. Strain gauge 296 is mountedwithin the inner housing assembly 204 to restrict rotation of the straingauge 296 relative thereto. First rotatable proximal drive shaft 212extends through strain gauge 296 to enable the strain gauge 296 toprovide a closed-loop feedback to a firing/clamping load exhibited byfirst rotatable proximal drive shaft 212. Electrical assembly 290 alsoincludes a slip ring 298 that is non-rotatably and slidably disposedalong drive coupling nut 244 of outer tube 206. Slip ring 298 is inelectrical connection with circuit board 294 and serves to permitrotation of first rotatable proximal drive shaft 212 and axialtranslation of drive coupling nut 244 while still maintaining electricalcontact of slip ring 298 with at least another electrical componentwithin adapter 200, and while permitting the other electrical componentsto rotate about first rotatable proximal drive shaft 212 and drivecoupling nut 244.

Still referring to FIG. 6, inner housing assembly 204 includes a hub 205that has a distally oriented annular wall 207 that defines asubstantially circular outer profile. Hub 205 includes a substantiallytear-drop shaped inner recess or bore that is shaped and dimensioned toslidably receive articulation bearing assembly 252 therewithin. Innerhousing assembly 204 further includes a ring plate 254 that is securedto a distal face of distally oriented annular wall 207 of hub 204 a.Ring plate 254 defines an aperture 254 a therethrough that is sized andformed therein so as to be aligned with second proximal drive shaft 214and to rotatably receive a distal tip thereof. In this manner, thedistal tip of the second proximal drive shaft 214 is supported andprevented from moving radially away from a longitudinal rotational axisof second proximal drive shaft 214 as second proximal drive shaft 214 isrotated to axially translate articulation bearing assembly 252.

Turning next to FIG. 10, in one example, the end effector 500 may beconfigured for a single use (“disposable loading unit—DLU”) and besimilar to those DLU's disclosed in U.S. Patent Application PublicationNo. 2010/0301097, entitled LOADING UNIT HAVING DRIVE ASSEMBLY LOCKINGMECHANISM, now U.S. Pat. No. 9,795,384, U.S. Patent ApplicationPublication No. 2012/0217284, entitled LOCKING MECHANISM FOR USE WITHLOADING UNITS, now U.S. Pat. No. 8,292,158, and U.S. Patent ApplicationPublication No. 2015/0374371, entitled ADAPTER ASSEMBLIES FORINTERCONNECTING SURGICAL LOADING UNITS AND HANDLE ASSEMBLIES, the entiredisclosures of each such references being hereby incorporated byreference herein. It is also contemplated that the end effector 500 maybe configured for multiple uses (MULU) such as those end effectorsdisclosed in U.S. Patent Application Publication No. 2017/0095250,entitled MULTI-USE LOADING UNIT, the entire disclosure of which ishereby incorporated by reference herein.

The depicted surgical instrument 100 fires staples, but it may beadapted to fire any other suitable fastener such as clips and two-partfasteners. In the illustrated arrangement, the end effector 500comprises a loading unit 510. The loading unit 510 comprises a proximalbody portion 520 and a tool assembly 600. Tool assembly 600 includes apair of jaw members including a first jaw member 610 that comprises ananvil assembly 612 and a second jaw member 700 that comprises acartridge assembly 701. One jaw member is pivotal in relation to theother to enable the clamping of tissue between the jaw members. Thecartridge assembly 701 is movable in relation to anvil assembly 612 andis movable between an open or unclamped position and a closed orapproximated position. However, the anvil assembly 612, or both thecartridge assembly 701 and the anvil assembly 612, can be movable.

The cartridge assembly 701 has a cartridge body 702 and in someinstances a support plate 710 that are attached to a channel 720 by asnap-fit connection, a detent, latch, or by another type of connection.The cartridge assembly 701 includes fasteners or staples 704 that aremovably supported in a plurality of laterally spaced staple retentionslots 706, which are configured as openings in a tissue contactingsurface 708. Each slot 706 is configured to receive a fastener or stapletherein. Cartridge body 702 also defines a plurality of cam wedge slotswhich accommodate staple pushers 709 and which are open on the bottom(i.e., away from tissue-contacting surface) to allow an actuation sled712 to pass longitudinally therethrough. The cartridge assembly 701 isremovable from channel 720 after the staples have been fired fromcartridge body 702. Another removable cartridge assembly is capable ofbeing loaded onto channel 720, such that surgical instrument 100 can beactuated again to fire additional fasteners or staples. Further detailsconcerning the cartridge assembly may be found, for example, in U.S.Patent Application Publication No. 2017/0095250 as well as various otherreferences that have been incorporated by reference herein.

Cartridge assembly 701 is pivotal in relation to anvil assembly 612 andis movable between an open or unclamped position and a closed or clampedposition for insertion through a cannula of a trocar. Proximal bodyportion 520 includes at least a drive assembly 540 and an articulationlink 560. In one arrangement, drive assembly 540 includes a flexibledrive beam 542 that has a distal end 544 and a proximal engagementsection 546. A proximal end of the engagement section 546 includesdiametrically opposed inwardly extending fingers 547 that engage ahollow drive member 548 to fixedly secure drive member 548 to theproximal end of beam 542. Drive member 548 defines a proximal portholewhich receives connection member 247 of drive tube 246 of first driveconverting assembly 240 of adapter 200 when the end effector 500 isattached to the distal end of the adapter 200.

End effector 500 further includes a housing assembly 530 that comprisesan outer housing 532 and an inner housing 534 that is disposed withinouter housing 532. First and second lugs 536 are each disposed on anouter surface of a proximal end 533 of outer housing 532 and areconfigured to operably engage the distal end of the adapter 200 asdiscussed in further detail in WO 2016/057225 A1.

With reference to FIG. 10, for example, anvil assembly 612 includes ananvil cover 630 and an anvil plate 620, which includes a plurality ofstaple forming depressions. Anvil plate 620 is secured to an undersideof anvil cover 630. When tool assembly 600 is in the approximatedposition, staple forming depressions are positioned in juxtaposedalignment with staple receiving slots of the cartridge assembly 701.

The tool assembly 600 includes a mounting assembly 800 that comprises anupper mounting portion 810 and a lower mounting portion 812. A mountingtail 632 protrudes proximally from a proximal end 631 of the anvil cover630. A centrally-located pivot member 814 extends from each upper andlower mounting portions 810 and 812 through openings 822 that are formedin coupling members 820. In at least one arrangement, the pivot member814 of the upper mounting portion 810 also extends through an opening634 in the mounting tail 632 as well. Coupling members 820 each includean interlocking proximal portion 824 that is configured to be receivedin corresponding grooves formed in distal ends of the outer housing 532and inner housing 534. Proximal body portion 520 of end effector 500includes articulation link 560 that has a hooked proximal end 562. Thearticulation link 560 is dimensioned to be slidably positioned within aslot in the inner housing. A pair of H-block assemblies 830 arepositioned adjacent the distal end of the outer housing 532 and adjacentthe distal end 544 of axial drive assembly 540 to prevent outwardbuckling and bulging of the flexible drive beam 542 during articulationand firing of surgical stapling apparatus 10. Each H-block assembly 830includes a flexible body 832 which includes a proximal end fixedlysecured to the distal end of the outer housing 532 and a distal end thatis fixedly secured to mounting assembly 800. In one arrangement, adistal end 564 of the articulation link is pivotally pinned to the rightH block assembly 830. Axial movement of the articulation link 560 willcause the tool assembly to articulate relative to the body portion 520.

FIGS. 11-15 illustrate an adapter 200′ that is substantially identicalto adapter 200 described above, except for the differences noted below.As can be seen in FIG. 11, the adapter 200′ includes an outer tube 206that has a proximal end portion 910 that has a first diameter “FD” andis mounted within the outer knob housing 202. The proximal end portion910 may be coupled to the inner housing assembly 204 or otherwisesupported therein in the manners discussed in further detail in WO2016/057225 A1 for example. The proximal end portion 910 extendsproximally from a central tube portion 912 that has a second diameter“SD”. In the illustrated embodiment, an end effector 500 is coupled to adistal end 914 of a shaft assembly 203 or outer tube 206. The outer tube206 defines a longitudinal axis LA that extends between the proximal endportion 910 and the distal end 914 as can be seen in FIG. 11. As can beseen in FIGS. 10 and 11, an outer sleeve 570 of the proximal bodyportion 520 of the end effector 500 has a distal end portion 572 and aproximal end portion 574. The proximal end portion 574 has a diameterSD′ that is approximately equal to the second diameter SD of the centraltube portion 912. The distal end portion 572 has a third diameter “TD”.In one arrangement, FD and TD are approximately equal and greater thanSD. Other arrangements are contemplated wherein FD and TD are not equal,but each are greater than SD. However, it is preferable that for mostcases FD and TD are dimensioned for endoscopic insertion through atypical trocar port, cannula or the like. In at least one arrangement(FIG. 11), the outer sleeve 570 is formed with a flat or scalloped side576 to facilitate improved access within the patient while effectivelyaccommodating the various drive and articulation components of theadapter 200′. In addition, by providing the central tube portion 912with a reduced diameter may afford the adapter 200′ with improvedthoracic in-between rib access.

In at least one arrangement, channel 720, which may be machined or madeof sheet metal, includes a pair of proximal holes 722 (FIG. 10) that areconfigured to align with a pair of corresponding holes 636 in the anvilcover 630 to receive corresponding pins or bosses 638 (FIG. 12) tofacilitate a pivotal relationship between anvil assembly 612 andcartridge assembly 701. In the illustrated example, a dynamic clampingassembly 550 is attached to or formed at the distal end 544 of theflexible drive beam 542. The dynamic clamping assembly 550 includes avertical body portion 552 that has a tissue cutting surface 554 formedthereon or attached thereto. See FIG. 10, for example. An anvilengagement feature 556 is formed on one end of the body portion 552 andcomprises an anvil engagement tab 557 that protrudes from each lateralside of the body portion 552. Similarly, a channel engagement feature558 is formed on the other end of the of the body portion 552 andcomprises a channel engagement tab 559 that protrudes from each lateralside of the body portion 552. See FIG. 15.

As indicated above, the anvil assembly 612 includes an anvil plate 620.The anvil plate 620 includes an elongate slot 622 that is configured toaccommodate the body portion 552 of the dynamic clamping assembly 550 asthe dynamic clamping assembly 550 is axially advanced during the firingprocess. The elongate slot 622 is defined between two anvil plate ledges624 that extend along each lateral side of the elongate slot 622. SeeFIG. 10. As the dynamic clamping assembly 550 is distally advanced, theanvil engagement tabs 557 slidably engage the anvil plate ledges 624 toretain the anvil assembly 612 clamped onto the target tissue. Similarly,during the firing operation, the body portion 552 of the dynamicclamping assembly 550 extends through a central slot in the channel 720and the channel engagement tabs 559 slidably engage channel ledges 725extending along each side of the central channel slot to retain thecartridge assembly 701 clamped onto the target tissue.

Turning to FIGS. 13 and 15, the channel 720 defines a docking areagenerally designated as 730 that is configured to accommodate thedynamic clamping assembly 550 when it is in its proximal most positionreferred to herein as an unfired or starting position. In particular,the docking area 730 is partially defined by planar docking surfaces 732that provides clearance between the channel engagement tabs 559 on thedynamic clamping assembly 550 to enable the cartridge assembly 701 topivot to a fully opened position. A ramped or camming surface 726extends from a distal end of each of the docking surfaces 732. Rampedsurface 726 is engaged by the dynamic clamping assembly 550 in order tomove the anvil assembly 612 and the cartridge assembly 701 with respectto one another. Similar camming surface could be provided on the anvilassembly 612 in other embodiments. It is envisioned that ramped surfaces726 may also facilitate the alignment and/or engagement between channel720 and support plate 620 and/or cartridge body 702. As the driveassembly 540 is distally advanced (fired), the channel engagement tabs559 on the dynamic clamping assembly 550 engage the corresponding rampedsurfaces 726 to apply a closing motion to the cartridge assembly 701thus closing the cartridge assembly 701 and the anvil assembly 612.Further distal translation of the dynamic clamping assembly 550 causesthe actuation sled 712 to move distally through cartridge body 702,which causes cam wedges 713 of actuation sled 712 to sequentially engagestaple pushers 709 to move staple pushers 709 vertically within stapleretention slots 706 and eject staples 704 into staple formingdepressions of anvil plate 620. Subsequent to the ejection of staples704 from retention slots 706 (and into tissue), the cutting edge 554 ofthe dynamic clamping assembly 550 severs the stapled tissue as thetissue cutting edge 554 on the vertical body portion 552 of the dynamicclamping assembly 550 travels distally through a central slot 703 ofcartridge body 702. After staples 704 have been ejected from cartridgebody 702 and a user wishes to use the same instrument 10 to fireadditional staples 704 (or another type of fastener or knife), the usercan remove the loading unit 510 from the adapter 200′ and replace itwith another fresh or unspent loading unit. In an alternativearrangement, the user may simply remove the spent cartridge body 702 andreplace it with a fresh unspent or unfired cartridge body 702.

During use of conventional adapters, debris and body fluids can migrateinto the outer tube of the adapter and detrimentally hamper theoperation of the adapter articulation and firing drive systems. Inegregious cases, such debris and fluids infiltrate into the innerhousing assembly of the adapter which may cause the electricalcomponents supported therein to short out and malfunction. Further, dueto limited access to the interior of the outer tube of the adapter, suchdebris and fluids are difficult to remove therefrom which can prevent orreduce the ability to reuse the adapter.

Turning to FIGS. 16 and 17, in one arrangement, at least one first seal230 is provided between the proximal inner housing assembly 204 and thefirst rotatable proximal drive shaft 212 to prevent fluid/debrisinfiltration within and proximal to the proximal inner housing assembly204. In addition, at least one second seal 232 is provided between thearticulation bar 258 and the outer tube 206 to prevent fluid/debris frompassing therebetween to enter the proximal inner housing assembly 204.At least one third housing seal 233 may be provided around a hub 205 ofthe proximal inner housing 204 to establish a seal between the hub 205and the outer knob housing 202. The first, second, and third seals 230,232, 233 may comprise, for example, flexible O-rings manufactured fromrubber or other suitable material.

In other arrangements, it may be desirable for the first and secondseals 230, 232 to be located in the adapter 200 distal to the electroniccomponents housed within the outer knob housing 202. For example, toprevent fluids/debris from fouling/shorting the slip ring assembly 298,it is desirable establish seals between the various moving components ofthe adapter 200 that are operably supported within the outer tube 206 ina location or locations that are each distal to the slip ring assembly298, for example. The seals 230, 232 may be supported in the wall of theouter tube and/or in mounting member 234 or other separate mountingmember/bushing/housing supported within the outer tube 206 andconfigured to facilitate axial movement of the distal drive member 248as well as the articulation bar 258 while establishing a fluid-tightseal between the bushing and/or outer tube and the distal drive member248 and the articulation bar 258. See FIGS. 18 and 20. In the embodimentillustrated in FIG. 19 for example, the first seal 230 may additionallyhave wiper features 231 that also slidably engage the distal drivemember 248 to prevent fluid/debris D from infiltrating in the proximaldirection PD into the proximal inner housing assembly 204. In at leastone arrangement to enable debris and fluids that have collected in theouter tube 206 distal to the first and second seals 230, 232, at leasttwo flushing ports 236, 238 are provided within the outer tube 206. Seee.g., FIGS. 18 and 20. The axially spaced flushing ports 236, 238 arelocated distal to the first and second seals 230, 232. A flushingsolution (e.g., cleaning fluid, saline fluid, air, etc.) may be enteredinto one or more port(s) to force the errant debris and fluid out of oneor more other port(s).

The ability to open the jaws of an endocutter to a large angle enablesmore tissue to be placed between them. In addition, having the abilityto open the jaws to a larger angle also makes it easier for a user toremove the tissue from between the jaws after the stapling process hasbeen completed which helps to simplify the cartridge reloading processwhen reloadable units are employed. Thus, it is desirable to optimizethe speeds and forces required to open the jaws of an end effector suchas an endocutter. In the past, a variety of methods have been employedto open the jaws of an endocutter. In one arrangement, a spring wasemployed to apply a biasing opening force to the jaws. However, suchspring opening arrangements may increase the amount of forces needed toclose the jaws. They may also have relatively limited motion and can bedifficult to install within the end effector.

FIGS. 22-25 illustrate use of an alternative channel 720′ of a secondjaw 700′. The channel 720′ may be identical to channel 720 describedabove, except for the differences noted below. In the illustratedarrangement, for example, the channel 720′ includes a positive channelopening feature 740 that comprises a ramp surface 742 that is located oneach side of a central slot 724 in the channel 720′. Each ramp 742terminates in a planar upper surface 744. As can be further seen in FIG.22, a channel ledge 725 is formed on each side of the elongate centralslot 724 on the top side of the channel 720′. During the firingoperation, the body portion 552 of the dynamic clamping assembly 550extends through the central slot 724 and the channel engagement tabs 559slidably engage the channel ledges 725 extending along each side of thecentral slot 724 to retain the cartridge assembly 701 clamped onto thetarget tissue.

FIGS. 22 and 23 illustrate a position of the dynamic clamping assembly550 as it is retracted in the proximal direction PD. As can be seen inthose Figures, the channel engagement tabs 559 have not yet contactedthe ramps 742 of the positive channel opening features 740. FIGS. 24 and25 illustrate initial contact of the channel engagement tabs 559 withthe ramp portions 742 of the corresponding positive channel openingfeatures 740. As can be seen in FIG. 25 the channel 720′ has started toopen (i.e., move away from the anvil assembly 612). FIG. 26 illustratesthe position of the dynamic clamping assembly 550 in its startingposition wherein the channel 720′ is in its fully open position. As canbe seen in that Figure, for example, the channel engagement tabs 559 arein engagement with the planar upper surfaces 744 of the ramps 742. Sucharrangement may be employed to open the jaws (anvil assembly 612 andcartridge assembly 701) without the use of a spring or springs. However,other variations are contemplated wherein an opening spring is alsoemployed in addition to the positive channel opening features 740.

FIGS. 27-29 illustrate an alternative arrangement where, in addition tothe positive channel opening features 740 on the channel 720′, positiveanvil opening features 627 are provided on a proximal end 621 of theanvil plate 620′. The anvil plate 620′ may be identical to anvil plate620 described above, except for the differences noted below. Thepositive anvil opening features 627 each comprise an anvil opening ramp628 provided on each side of the elongate slot 622 (see FIG. 10). Asdiscussed above, the anvil plate has an elongate slot 622 that definestwo elongate ledges 624 upon which anvil engagement tabs 557 of thedynamic clamping assembly 550 ride. The positive channel openingfeatures 740 on the channel 720′ are longitudinally offset from thepositive anvil opening features 627 on the anvil plate 620′. In theillustrated example, the positive channel opening features 740 on thechannel 720′ are distal to the positive anvil opening features 627 onthe anvil plate 620′. FIG. 27 illustrates initial contact of the channelengagement tabs 559 with the ramp surfaces 742 of the positive channelopening features 740. For reference purposes, the distance between thedistal edge of each channel engagement tab 559 and the jaw axis JA islabeled as distance PDD₁. FIG. 28 illustrates the position of thedynamic clamping assembly 550 after the channel engagement tabs 559 havemoved up the ramps 742 onto the planar upper surfaces 744 of thepositive channel opening features 740. When in that position, the anvilengagement tabs 557 on the dynamic clamping assembly 550 have contactedthe anvil opening ramps 628 of the anvil opening features 627. Thus,comparing the proximal travel distance of the dynamic clamping assemblybetween FIGS. 27 and 28: PDD₂>PDD₁. FIG. 29 illustrates position of thedynamic clamping assembly 550 after it has moved back to its startingposition and the anvil engagement tabs 557 on the dynamic clampingassembly 550 have completely moved past the anvil opening ramps 628 ofthe anvil opening features 627 and the jaws 700′ and 610′ are in theirfully open positions. Thus, comparing the proximal travel distance ofthe dynamic clamping assembly between FIGS. 28 and 29: PDD₃>PDD₂. Suchpositive jaw opening features 740, 627 use either/both longitudinalforces to drive the opening of the jaws or orthogonal forces to drivethe opening motions. In the above described example, the positive jawopening features are longitudinally offset. In other arrangements,however, the anvil engagement tabs 557 contact the ramps 628 atapproximately the same time that the tabs 559 contact the ramps 742.

Another feature employed by a channel 720″ relates to closure rampsformed on the channel 720″. The channel 720″ may be identical to channel720′ or 720 described above, except for the differences noted below. Ascan be seen in FIGS. 30-32, for example, a first closure ramp segment726 a is formed on each side of the elongate slot (not shown) in thechannel 720″. Each first closure ramp segment 726 a transitions into ahorizontal plateau ramp segment 727 which in turn transitions into asecond closure ramp segment 728. Each second closure ramp segment 728transitions to a corresponding channel ledge 725. In one arrangement,the slope of each of the first closure ramp segments 726 a is the sameas the slope of the second closure ramp segments 728. In otherarrangements, the slopes are different. FIG. 30 illustrates the positionof the channel engagement tabs 559 on the dynamic clamping assembly 550when the jaws 610″, 700″are in their fully open position. FIG. 31illustrates a position of the dynamic clamping assembly 550 after it hasbeen moved distally so as to bring the channel engagement tabs 559 intosliding engagement with the proximal closure ramp segments 726 a so asto begin the jaw closure process. FIG. 32 illustrates another positionof the dynamic clamping assembly 550 after it has further moved in thedistal direction DD so as to bring the channel engagement tabs 559 intosliding engagement with the plateau ramp segment 727 and prior tostarting a firing stroke wherein the channel engagement tabs 559slidably engage the channel ledges 725 on the channel 720″.

Another desirable attribute for surgical end effectors relates to “jawaperture”. “Jaw aperture” may refer to the angle between a stapleforming surface on the anvil plate and a tissue contacting surface ofthe staple cartridge. In existing versions of DLU's, SULU's and MULU's,the upper channel engagement feature or tab on the dynamic clampingunit, when the dynamic clamping unit is in its proximal most or startingposition, is generally positioned directly above or distal to a jawpivot axis about which the cartridge assembly pivots relative to theanvil assembly. Such arrangements commonly limit the jaws from openingrelative to each other more than 18-23 mm, for example.

One aspect of the present disclosure involves the formation of a“docking” or “parking” area for the dynamic clamping member when thedynamic clamping member is in its proximal most or starting position.For example, FIG. 33 illustrates an end effector 1500 that includes aparking or docking area 730 for the dynamic clamping assembly 550 whenthe dynamic clamping assembly 550 is in its proximal most or startingposition. In accordance with another aspect, as was described above, thedynamic clamping assembly 550 includes a vertically extending bodyportion 552 and has an anvil engagement feature 556 that comprises ananvil engagement tab or flange 557 that extends from each lateral sideof the body portion 552. In addition, the dynamic clamping assembly 550includes a channel engagement feature 558 that comprises a channelengagement tab or flange 559 that extends laterally from each lateralside of the body portion 552. As used in this context, the term “flange”connotes a planar feature that extends transversely or perpendicularlyfrom the body portion 552. As such, when viewed from an end, the dynamicclamping assembly 550 resembles an I-beam configuration and may bereferred to herein as a dynamic I-beam clamping member. As can be seenin FIG. 33, a portion of the channel engagement flanges 559 extendproximal of the pin 638 that pivotally couples the cartridge assembly701 to the anvil assembly 612 and which defines a jaw pivot axis JAabout which the anvil and channel may move between open and closedpositions. In addition, although not viewable in FIG. 33, in at leastone arrangement, a portion of each of the anvil engagement flanges 557also extends proximal to the jaw pivot axis JA when the dynamic I-beamclamping assembly 550 is in the parking or starting position. Thisdistance is labeled as distance “PDD₄” in FIG. 33, for example.

A lower end of the body portion 552 of the dynamic I-beam clampingassembly 550 extends through an elongate slot (not shown) in the channel1720. A first lower surface 1726 is formed on a proximal end 1725 of thechannel 1720 on each side of the elongate slot. Each first lower surface1726 terminates distally in a second closure cam surface or ramp 1727that corresponds to each channel engagement flange 559 on the dynamicI-beam clamping assembly 550. When the channel engagement flanges 559engage their corresponding second closure cam surface 1727, thecartridge assembly and the anvil assembly 612 start to close or pivottoward each other by virtue of the interaction of the anvil engagementflanges with corresponding surfaces on the anvil plate and the cammingaction of the channel engagement tabs with the corresponding secondclosure cam surfaces 1727 on the channel 1720. Once the dynamic I-beamclamping assembly 550 has moved distally to a point wherein the channelengagement flanges 559 disengage the second closure cam surfaces 1727,the channel engagement flanges 559 engage corresponding third closuresurfaces 1728 on the bottom of the channel 1720 to keep the anvilassembly and cartridge assembly closed and resist deflection throughoutthe firing process (i.e., as the dynamic I-beam clamping assembly isdistally advanced through the cartridge assembly 701).

In the illustrated arrangement, when the dynamic I-beam clampingassembly 550 is in the proximal most or starting position, the channelengagement flanges 559 are proximal to the second closure cam surfaces1727 yet are in contact with the first lower surface 1726 to limit orotherwise restrict the jaws (anvil assembly 612, cartridge assembly 701)to that amount of jaw aperture represented as angle Θ₁ between a stapleforming surface 625 on the anvil plate 620 and the tissue contactsurface 708 of the cartridge body 702). In the illustrated arrangement,for example, the dynamic I-beam clamping assembly 550 may have to movedistally a distance X from the starting position until the channelengagement flanges 559 start to cammingly engage the second closure camsurfaces 1727 to commence the jaw closure process. In that arrangement,the actuation sled 1712 has a length SL and the cartridge body 702 has anose portion 718 that has a length NL that extends beyond the distal endof the channel 1720.

In accordance with another general aspect, FIG. 34 illustrates anotherend effector 1500′ that includes a parking or docking area 730′ for thedynamic clamping assembly 550 when the dynamic clamping assembly 550 isin its proximal most or starting position. A first lower surface 1726′is formed on a proximal end 1725 of the channel 1720′ on each side ofthe elongate slot. Each first lower surface 1726′ terminates distally ina second closure cam surface or ramp 1727′ that corresponds to eachchannel engagement flange 559 on the dynamic I-beam clamping assembly550. When the channel engagement flanges 559 cammingly engage theircorresponding second closure cam surface 1727′, the cartridge assembly701 and the anvil assembly 612 start to close or pivot toward each otherby virtue of the interaction of the anvil engagement flanges 557 withcorresponding surfaces on the anvil plate 620 and the camming action ofthe channel engagement flanges 559 with the corresponding second closurecam surfaces 1727′ on the channel 1720′. Once the dynamic I-beamclamping assembly 550 has moved distally to a point wherein the channelengagement flanges 559 disengage the second closure cam surfaces 1727′,the channel engagement flanges 559 engage corresponding third closuresurfaces 1728′ on the bottom of the channel 1720 to keep the anvilassembly and cartridge assembly closed throughout the firing process(i.e., as the dynamic I-beam clamping assembly is distally advancedthrough the cartridge assembly 701′ to its ending position).

In the illustrated arrangement, when the dynamic I-beam clampingassembly 550 is in the proximal most or starting position, the channelengagement tabs 559 are located in abutting engagement with the secondclosure cam surfaces 1727′ and are not spaced therefrom. Thus, when thedynamic I-beam clamping assembly is actuated to move distally, thechannel engagement flanges 559 immediately start to cam the cartridgeassembly 701′ closed. Such arrangement provides a jaw aperture angle Θ₂that is greater than Θ₁, for example. Thus, unlike the second jaw 700described above, the dynamic I-beam clamping assembly 550 does not movedistally any distance before it begins to cam the second jaw 700′closed. In that arrangement, the actuation sled 1712′ has a length SL′and a nose portion 718′ that has a length NL′ that extends beyond thedistal end of the channel 1720′. When compared to the above describedarrangement, SL′<SL and NL′<NL, which generally leads to improvedmaneuverability of the end effector 1500′. In other arrangements, thereis at least a portion of the I-beam clamping assembly distal advancementwherein the I-beam clamping assembly is not in contact with both jawsbefore it enters its closure strike portion wherein it begins to opposethe jaws toward one another.

During the firing process, a considerable amount of friction isgenerally experienced between the dynamic clamping assembly and theanvil assembly and cartridge assembly. Typically, the dynamic clampingassembly is fabricated from steel and employs steel pins or flanges forcontacting the corresponding ledges on the anvil plate and the channelwhich are also fabricated from steel. As dynamic clamping member isadvanced distally, the upper and lower steel pins are brought intoslidable frictional contact with the corresponding ledges on the anvilplate and channel to clamp the anvil assembly and cartridge assemblyonto the target tissue and drive the actuation sled distally to fire thestaples and cut the stapled tissue. Such frictional contact can oftenresult in the erosion of the steel pins and ledges which cansignificantly reduce the useful life of the end effector. In addition,the increased friction between the pins or flanges of the dynamicclamping assembly and the anvil assembly and cartridge assemblyincreases the amount of firing force that is required to drive thedynamic clamping assembly from its starting to ending position throughthe clamped tissue. These large firing forces dictate that the relatedcomponents within the end effector as well as within the adapter must besufficiently capable of accommodating such high firing forces. Thisrequires that the various components be manufactured from stronger andoften thicker material in an operational environment where operationalspace is limited (e.g., within the outer tube of the adapter). Thus,higher firing forces lead to more complicated designs and materialcompositions which lead to increased instrument costs.

Another aspect of the present disclosure comprises a dynamic clampingassembly 1550 as illustrated in FIG. 35. In the illustrated example, thedynamic clamping assembly 1550 comprises a vertically extending bodyportion 1552 that has a tissue cutting portion 1554 formed therein. Thebody portion 1552 is sized to be slidably received within the elongateslot 622 of the anvil plate 620 (FIG. 10) as well as within the centralslot 724 of the channel 720 (FIG. 15). The cartridge assembly 701generally includes a proximal end 705 and a distal end and 707 anddefines a longitudinal axis LA therebetween. See FIGS. 10 and 15. Thedynamic clamping assembly 1550 further includes at least one channelengagement feature 1558. In the illustrated arrangement, a channelengagement feature 1558 extends from each lateral side 1553 of the bodyportion 1552. In one example, each channel engagement feature 1558comprises a channel engagement flange 1580 that has a distal end 1582, aproximal end 1584, and a channel ledge engagement surface 1586 extendingtherebetween. The channel ledge engagement surface 1586 is configured toslidably ride on or engage a corresponding one of the channel ledges 725formed on each side of the central slot 724 in the channel 720. In theillustrated arrangement, a distal end 1587 of the channel ledgeengagement surface 1586 is radiused to reduce friction between thechannel ledge engagement surface 1586 and the channel ledges 725. Inaccordance with another aspect, in at least one arrangement, the channelledge engagement surface 1586 angles from the proximal end 1584 to thedistal end 1584 away from the longitudinal axis LA. For example, in FIG.35, axis CLA is parallel to the longitudinal axis LA and may also beparallel to the upper surface 729 of each channel ledge 725 when thecartridge assembly 701 is in the closed position. In at least onearrangement, for example, the channel ledge engagement surface 1586angles away from axis CLA a channel angle θ_(CA). Stated another way,the channel ledge engagement surface 1586 is not parallel with the uppersurface 729 of a corresponding one of the channel ledges 725 when thecartridge assembly 701 is in the closed position. In one arrangement,θ_(CA) may be approximately 0.5°, for example. Other angles, however,are contemplated. Such arrangement may lower point loads on the distalend 1582 of the flange 1580. In an alternative arrangement (not shown),the anvil engagement surface on each of the anvil engagement flanges mayhave two distinct linear segments wherein one segment is arranged at anangle of the positive anvil opening ramps 628 (FIGS. 27-29) and theother linear segment may match the angle of each of the anvil plateledges 624. In still other alternative arrangements (not shown) thelength of each of the channel engagement flanges may be longer than thelength of the anvil engagement flanges which may allow the loads to bedistributed over a larger area of the channel ledge which may lower thepotential local contact loads and lower galling. Similar favorableresults may be obtained wherein each of the anvil engagement flanges arelonger than the channel engagement flanges.

Still referring to FIG. 35, the dynamic clamping assembly 1550 furtherincludes at least one anvil engagement feature 1556. In the illustratedarrangement, an anvil engagement feature 1556 extends from each lateralside 1553 of the body portion 1552. In one example, each anvilengagement feature 1556 comprises a flange 1590 that has a distal end1592, a proximal end 1594 and an anvil ledge engagement surface 1596extending therebetween. The anvil ledge engagement surface 1596 isconfigured to slidably ride on or engage a corresponding one of theanvil plate ledges 624 formed on each side of the elongate slot 622 inthe anvil plate 620. In the illustrated arrangement, a distal end 1597of the anvil ledge engagement surface 1596 is radiused to reducefriction between the anvil ledge engagement surface 1596 and the anvilplate ledges 624. In accordance with another aspect, in at least onearrangement, the anvil ledge engagement surface 1596 angles from theproximal end 1594 to the distal end 1592 away from the longitudinal axisLA. For example, in FIG. 35, axis ALA is parallel to the longitudinalaxis LA and may also be parallel to the lower surface 626 of each anvilplate ledge 624 when the anvil assembly 612 is in the closed position.In at least one arrangement, for example, the anvil ledge engagementsurface 1596 angles away from axis ALA an anvil angle Θ_(AA). Statedanother way, the anvil ledge engagement surface 1596 is not parallelwith the lower surface of a corresponding one of the anvil plate ledges624 when the anvil plate 620 is in the closed position. In onearrangement, Θ_(AA) may be approximately 1°, for example. Other angles,however, are contemplated. Such arrangement may lower the point loads onthe distal end 1592 of the flange 1590. Other arrangements arecontemplated wherein only the channel ledge engagement surfaces or theanvil ledge engagement surfaces are angled. For example, in anotherarrangement, the channel ledge engagement surface of each channelengagement flange may be approximately parallel to the longitudinal axisLA and the anvil ledge engagement surface on each of the anvil ledgeengagement flanges are angles as described herein. In anotherarrangement, the channel ledge engagement surface of each channel ledgeengagement flange is angled as described above, but the anvil ledgeengagement surface of each anvil engagement flange is not angledrelative to the longitudinal axis LA, but rather is approximatelyparallel thereto.

Turning to FIG. 36, in accordance with yet another aspect of the presentdisclosure, each of the anvil engagement flanges 1590 is coated with aceramic material 1598. One form of ceramic coating that may be employedcomprises ceramic coatings that may comprise, for example, diamond-likecarbon (DLC), titanium nitride (TiN), zirconium nitride (ZrN),titanium-niobium-nitride (TiNbN), calcium phosphates (Ca₃(PO₄)₂), and ahydroxyapatite (Ca₁₀(PO₄)6°(OH)₂). Although not strictly regarded as acoating(but as a native oxide layer), another popular metallic-ceramiccomposite is an in-situ grown monoclimic zirconia onto a zirconiumniobium alloy (i.e., oxidized zirconia, OxZr). A similar coating may beapplied to each of the channel engagement flanges 1580. In addition, asimilar ceramic coating may be applied to the lower surface 626 of eachof the anvil plate ledges 624 as well as to the upper surface 729 ofeach channel ledge 725. In the alternative, the entire anvil plateledges 624 and the entire channel ledges 725 may be coated with theceramic coating. Such coating may be applied using 3D printingtechnology and form a surface with significantly higher hardness thanthe material to which it is applied and can also be highly polished toresult in significantly lower frictional drag between those componentsduring firing. Other methods of applying coatings that may beeffectively employed include but are not limited to indirect resincomposite—aerosol deposition as well as plasma and vapor deposition.

In accordance with another general aspect of the present disclosure, oneform of the dynamic clamping member 1550 includes at least one channelflange insert 1585 that is embedded into the corresponding channelengagement flange 1580. In the illustrated example, two channel flangeinserts 1585 are embedded into each channel flange 1580. Still referringto FIG. 36, the dynamic clamping member 1550 further includes at leastone anvil flange insert 1595 that is embedded into the correspondinganvil engagement flange 1590. In the illustrated example, two anvilflange inserts 1595 are embedded into each anvil flange 1590. As shown,each channel flange insert 1585 and each anvil flange insert 1595 has arectangular cross-sectional shape. However, other numbers, sizes andshapes of channel flange and anvil flange inserts are contemplated. Inat least one example, each anvil flange insert 1595 extends from theouter coating or cover 1598.

In accordance with another general aspect, for those arrangementswherein each channel ledge 725 and each anvil plate ledge 624 isfabricated from metal (or other material) having, for example, ahardness measured on the Rockwell C scale of approximately HRC 39-45,each of the channel flange inserts 1585 and each of the anvil flangeinserts 1595 may be fabricated from a material having a hardness valuethat is greater than the hardness value of the channel ledges 725 andthe anvil plate ledges 624. For example, the channel flange inserts 1585and the anvil flange inserts 1595 may be fabricated from ceramicmaterials that include, but are not limited to for example, alumina(Al₂O₃), zirconia (ZrO₂), zirconia-toughened alumina (ZTA), aluminamatrix composites (AMC), alumina-toughened zirconia (ATZ), siliconnitride (Si₃N₄), and hydroxyapatite (Hap) that has a hardness value ofapproximately HRC 55-70. In these instances, the material comprising thechannel flange inserts and the anvil flange inserts has a crystallinestructure that differs from the crystalline structure(s) of thematerial(s) from which the anvil plate ledges and channel ledges arefabricated.

FIG. 37 is a cross-sectional view of the central body portion 1552 ofthe dynamic clamping assembly 1550 taken along line 37-37 in FIG. 36. Inthe illustrated example, the central body portion 1552 comprises acentral region 1555 that may be fabricated from 420 or 440 SS—highRockwell C 400 series stainless steel. A ceramic side region 1559 isattached to each lateral side of the central region. Each ceramic sideregion may have a hardness that is greater than the hardness of thecentral region. Hardened inserts 1551 are also attached to the surfacesof the ceramic side regions. The hardened inserts may be fabricated from420 or 440 SS—high Rockwell C 400 series stainless steel.

FIGS. 38 and 39 illustrate another dynamic clamping assembly 1550′ thatis similar to the dynamic clamping assembly 1550 except for thedifferences discussed below. As can be seen in FIG. 38, a channel ledgeengagement surface 1586′ of a channel engagement flange 1580′ and ananvil ledge engagement surface 1596′ of an anvil engagement flange 1590′are each approximately parallel to the longitudinal axis LA. Each of thechannel engagement flanges 1580′ as well as a body portion 1552 of thedynamic clamping assembly 1550′ are coated with a material 1560 that maycomprise a coating material sold under the trademark MEDCOAT/2000™ bythe Electrolizing Corporation of Ohio. In the alternative, a Nitridecoating may be employed. These coatings may be applied after the tissuecutting portion 1554 has been formed and sharpened. Applying the coatingof material 1560 to the tissue cutting portion 1554 may enhance andimprove its sharpness.

FIGS. 40-43 depict an articulation locking system 5900 for locking anarticulation link 5560 of a surgical end effector 5500 in the form of aloading unit 5510 (DLU or MLU). The loading unit 5510 is identical tothe loading unit 510 except for the differences noted below. As can beseen in FIGS. 40-43, the illustrated articulation locking system 5900comprises a laterally displaceable lock member 5910 that includes lockteeth 5912 that are configured to lockingly engage lock grooves 5564formed in a proximal end 5562 of the articulation link 5560. The lockingsystem 5900 further comprises a locking cam 5920 that is pivotallycoupled to an outer housing 5532. Outer housing 5532 is similar to outerhousing 532 described above. The lock member 5910 is constrained to movelaterally (directions L₁ and L₂) between two mounting features 5918mounted or formed within the outer housing 5532 as can be seen in FIGS.42 and 43. The locking cam 5920 includes a cam actuator 5922 that isconfigured to operably interface with a flexible drive beam 5542 of adrive assembly 5540. As can be most particularly seen in FIG. 40, a camopening 5543 is provided in the flexible drive beam 5542 for receivingthe cam actuator 5922 when the drive assembly 5540 is in the unactuatedor unfired position. When in a starting or unfired position, the lockingcam 5920 is biased into an unactuated position by a pair of biasingmembers 5940 that bear upon the lock member 5910 to laterally displacethe lock member 5910 in the lateral direction L₁. When in that position,the lock teeth 5912 of the lock member 5910 are out of engagement withthe lock grooves 5564 formed in the proximal end 5562 of thearticulation link 5560 such that the articulation link 5560 may beaxially moved in the proximal direction PD and distal direction DD bythe articulation bar 258 of an adapter to which the end effector 5500 isoperably attached. Thus, when in the unlocked position illustrated inFIG. 42, the articulation link 5560 may be axially moved to articulatethe end effector into a desired articulated position. Once the clinicianhas articulated the end effector into the desired orientation, the driveassembly 5540 is actuated to distally advance the flexible firing beam5542. As the firing beam 5542 is advanced distally, the cam actuator5922 causes the locking cam 5920 to pivot and bias the lock member 5910in the lateral direction L₂ so as to bring the locking teeth 5912thereof into locking engagement with the lock grooves 5564. As can beseen in FIGS. 40-43, the lock grooves 5564 are defined between lockteeth 5566. The lock teeth 5566 each have pointed ends 5568 that areconfigured to cooperate with pointed ends 5914 on lock teeth 5912 toprovide axial lead in assistance into the locked position.

FIGS. 44-54 illustrate a drive assembly locking system 6900 forpreventing the axial advancement of a dynamic clamping assembly 550 of asurgical end effector 500′ unless an unfired cartridge 702 has beenproperly loaded into the channel 720 of the end effector 500′, forexample. As used in this context, the term “unfired cartridge” meansthat the cartridge 702 has not been fired and contains all of itsstaples 704 with the actuation sled 712 in its starting and unfired orready to fire position therein. As can be seen in FIG. 44, in oneexample, the drive assembly locking system 6900 comprises lock member6902 that is supported by an inner housing 534 of the end effector 500′and is configured to retainingly engage a body portion 552 of a dynamicclamping assembly 550. As can be seen in FIGS. 45-47, the lock member6902 comprises two lateral lock arms 6904 that each has a latch feature6906 thereon. The lateral lock arms 6904 are normally biased inward suchthat the latch features 6906 thereon retainingly engage the body portion552 of the dynamic clamping assembly 550 when the dynamic clampingassembly 550 is located in its starting/unfired position. Thus, when thelatch features 6906 are in retaining engagement with the dynamicclamping assembly 550, the dynamic clamping assembly 550 is preventedfrom being driven distally (fired).

FIGS. 44 and 45 illustrate a portion of the end effector 500′ wherein anunfired cartridge 702 has been properly loaded into the end effector500′. The unfired cartridge 702 supports an actuator sled 712 in anunactuated position therein wherein portions of cam wedges 713 of theactuator sled 712 engage the latch features 6906 and bias each of thelateral lock arms 6904 out of locking engagement (arrows UL in FIG. 45)with the body portion 552 of the dynamic clamping assembly 550. When inthat unlocked position (FIGS. 45 and 46), the dynamic clamping assembly550 can be driven distally to fire the staples in the cartridge 702(FIG. 47) and cut the tissue clamped therein. Once the dynamic clampingassembly 550 has been distally driven to its ending position within thecartridge 702, it is then retracted in the proximal direction PD back toits starting position. The actuation sled 712 remains at the distal endof the cartridge 702.

FIG. 48 illustrates the lock member 6902 after the dynamic clampingmember has been driven distally out of its starting position. As can beseen in that Figure, the lock arms 6902 are biased inwardly (arrows LD).During the retraction process, the dynamic clamping assembly 550 willcontact the latch features 6906 as it is retracted in the proximaldirection PD as shown in FIG. 49. As the dynamic clamping assembly 550contacts the latch features 6906, the lock arms 6904 are biasedlaterally outward (arrows UL) until the dynamic clamping assembly 550 isfully retracted into the starting position at which point the lock arms6904 move back to the locked configuration wherein the latch features6906 once again retainingly engage the dynamic clamping assembly 550.See FIG. 50. Thus, the dynamic clamping assembly 550 is once againprevented from being driven distally until a new unfired cartridge isloaded into the channel. Should the clinician attempt to refire thedynamic clamping member 550 before the now spent cartridge is replaced,they will be unable to do so. Further, should the clinician unwittinglyload a partially fired cartridge into the end effector 500′, the lockmember 6902 will prevent the dynamic clamping assembly 550 from beingfired, because the actuation sled in the partially fired cartridge willnot be in the starting position to unlock the lock member 6902. FIG. 51illustrates the end effector 500′ with the jaws 610, 700 in the fullyopen position. FIG. 52 illustrates the dynamic clamping assembly 550 ina position corresponding to the fully open position. FIG. 53 illustratesthe end effector 500′ with the jaws 610, 700 in the fully closedposition. FIG. 54 illustrates the position of the dynamic clampingassembly 550 after it has moved the jaws 610, 700 to the fully closedposition but prior to firing. Because the jaws 610, 700 are moved fromthe fully open to fully closed position by the dynamic clamping assembly550, the lock member 6902 is configured to permit such axial movement ofthe dynamic clamping assembly 550 while still being in the lockedposition. As can be seen in FIGS. 52 and 54, for example, when the lockarms 6904 are in the normally locked position, an axial pocket 6908 isdefined therebetween to permit the axial movement of the dynamicclamping assembly 550 that is required to open and close the jaws 610,700 without permitting the dynamic clamping assembly 550 from beingdistally moved beyond the fully closed position unless an unfiredcartridge is loaded into the channel of the end effector.

FIGS. 55-57 illustrate another drive assembly locking system 6920 forpreventing the axial advancement of the dynamic clamping assembly 550 ofan end effector of an adapter of the type disclosed herein unless acartridge 702′ has been properly loaded into the channel of the endeffector. In this example, the cartridge 702′ is formed with a pair ofproximally extending unlocking features 6930 that are configured tounlocking engage a pivoting lock member 6922. The pivoting lock member6922 is configured to pivot between a locked position wherein a lockoutfeature 6924 is received within a lock cavity 543′ that is formed in aflexible drive beam 542′ (FIG. 55) of the end effector. When the lockoutfeature 6924 is received within the lock cavity 543′, the drive beam542′ (and the dynamic clamping assembly 550 coupled thereto) cannot beadvanced distally to fire staples that are stored in the cartridge 702′.The lock member 6922 also includes a distally extending unlocking arm6926 that corresponds to each unlocking feature 6930 on the cartridge702′. When the cartridge 702′is properly loaded into the end effector,the unlocking features 6930 engage the corresponding unlocking arms 6926to pivot the lock member 6922 to the unlocked position wherein thelockout feature 6924 is pivoted out of the lock cavity 543 to therebypermit the drive beam 542′ to be distally advanced to fire the dynamicclamping assembly 550. In an alternative arrangement, the proximallyextending unlocking features 6930 are not formed on the cartridge 702,but instead are formed on the actuation sled (not shown) that issupported in the cartridge. When the actuation sled is in the unactuatedposition (corresponding to an unfired or fresh cartridge) the unlockingfeatures thereon will engage the unlocking arms 6926 on the lock member6922 to pivot the lock member into the unlocked position.

FIG. 58 illustrates another cartridge 702″ arrangement that employs aflexible circuit member 6940 that is attached to a deck surface 6952 ofthe cartridge body 6950. In the illustrated arrangement, a raised deckportion 6954 extends on each side of an elongate slot 6951 in thecartridge body 6950 to detect the position of a dynamic clamping memberof the end effector. The flexible circuit 6940 may include a circuitmicrochip 6942 that communicates with the circuit board 294 in theadapter in which it is mounted. The flexible circuit member 6940includes contacts 6944 that electrically contact corresponding contacts(not shown) in a channel of the end effector which are ultimatelyconnected to a circuit board 294 (FIG. 6) of an adapter or other controlboard arrangement therein. The flexible circuit member 6940 mayfacilitate better control of the advancement of the dynamic clampingassembly by monitoring its location and using that information tocontrol a firing motor in the surgical instrument. For example, sucharrangement may be employed to change the speed or power capability atthe beginning or end of the firing stroke. This information may also beused to change the maximum acceptable torque limits at the verybeginning of the firing stroke and at the end of the firing stroke. Inother arrangements, a deformable member may be provided within the MULUopening for the distal end of the firing rod which could allow for ashock absorbing stop at the end of the stroke but also as a leadingforce indicator on the current of the motor as the rod gets near theends of its metallic slot travel. Placement of a portion of the MULU orDLU which has a high moment of inertia but also a higher elastic straincapability would allow this part of the ground force return system toabsorb any high force spikes that occur due to the motor's inability todynamically brake fast enough in case of a series of metallic componentsinadvertently colliding. This elongateable and preferably elasticcomponent may be in series with the ground and DLU bayonet attachment.Such arrangement may comprise plastic bendable features that exist atthe attachment point of the metal articulation pivot I-plates. Sucharrangement may also comprise a separate part in cooperation with theseattachments and the bayonet connection which has a stretchable aspectwith maximum stretch limiting secondary features that allow for limitedstretch length but tolerate impact deflections.

During a surgical procedure, it is desirable for a clinician to be ableto monitor the progress or location of a dynamic clamping member of theadapter being employed. FIGS. 59-64 illustrate another end effector 2500that includes means for ascertaining a position of a dynamic clampingassembly 550 of the end effector 2500 to both close and serially firestaples from a staple cartridge while continuing to further close thejaws of the end effector 2500. In one form, the end effector 2500includes a tool assembly 2600 that may be identical to the tool assembly600 described above, except for the differences discussed herein. Thetool assembly 2600 includes a first jaw 2610 that comprises an anvilassembly 2612 and a second jaw 2700 that that comprises a cartridgeassembly 2701. In one form, the anvil assembly 2612 comprises an anvilplate 2620 that includes a staple forming undersurface 2626 which isconfigured in confronting relationship with the cartridge assembly 2701.An anvil cover 2630 is attached to the anvil plate 2620.

In the illustrated example, the anvil cover 2630 comprises a bodyportion 2632 that extends from a proximal end 2642 to a distal end 2644.As shown, the anvil cover 2630 may also include a pair of downwardlyextending tissue stops 2646 that serve to prevent target tissue fromextending proximally past the proximal-most staples that are stored inthe cartridge assembly 2701. FIGS. 60 and 61 illustrate the toolassembly 2600 wherein the dynamic clamping assembly 550 is in a startingposition. Stated another way, in FIGS. 60 and 61, the dynamic clampingassembly 550 is in its proximal-most position. As can be mostparticularly seen in FIG. 59, for example, the anvil cover body portion2632 comprises a first lateral side portion 2634 and a second lateralside portion 2636 that is laterally spaced from the first lateral sideportion 2634. A plurality of first jaw stiffener features 2650, 2652extend between the first and second lateral side portions 2634 and 2636.The stiffener features 2650 and 2652 are longitudinally offset from eachother to define a first jaw opening 2654 therebetween. Additionally, thefirst jaw stiffener feature 2650 is longitudinally separated from theproximal end portion 2642 by a proximal first jaw opening 2656 and thesecond jaw stiffener feature 2652 is longitudinally separated from thedistal end portion 2644 by a distal first jaw opening 2658 as shown.

Turning next to FIG. 60, the second jaw 2700 comprises a channel 2720that is configured to operably support the cartridge assembly 2701therein. The channel 2720 comprises a channel body portion 2721 thatincludes a proximal end portion 2723 and a distal end portion 2726. Thechannel 2720 further comprises a primary lateral side portion 2727 and asecondary lateral side portion 2728 that is laterally spaced from theprimary lateral side portion 2727. A plurality of second jaw stiffenerfeatures 2734, 2735 extend between the primary and secondary lateralside portions 2727 and 2728. The second jaw stiffener features 2734 and2735 are longitudinally offset from each other to define a second jawopening 2736 therebetween. Additionally, the second jaw stiffenerfeature 2734 is longitudinally separated from a proximal end portion2725 by a proximal second jaw opening 2737 and the second jaw stiffenerfeature 2735 is longitudinally separated from the distal end portion2726 by a distal second jaw opening 2738 as shown.

The first jaw stiffeners 2650, 2652 and the second jaw stiffeners 2734,2735 serve to stiffen the first and second jaws 2610, 2700, respectivelywhile clamping target tissue therebetween. Additionally, thelongitudinally displaced openings 2654, 2656, 2658, 2736, 2737, 2738enable the clinician to view the progress and location of the dynamicclamping assembly during firing (e.g., the portion of the distaladvancement of the dynamic clamping assembly 550 wherein the staples arefired from the cartridge assembly 701). For example, as shown in FIG.62, reference axis A₁ corresponds to the locations of the proximal-moststaples or fasteners in the cartridge assembly 2701. Reference axis A₂corresponds to the locations of the distal-most staples or fasteners inthe cartridge assembly 2701. In the illustrated example, the proximalsecond jaw opening 2737 extends distally from the proximal-most fastenerlocations (represented by reference axis A₁) to the second jaw stiffenerfeature 2734 and the distal first jaw opening 2658 extends proximallyfrom the distal most fastener locations (represented by axis A₂) to thefirst jaw stiffener feature 2652.

Still referring to FIG. 62, the proximal end portion 2642 of the firstjaw 2610 is in vertical registration (e.g., directly above) with theproximal second jaw opening 2737 in the second jaw 2700 when the jaws2610, 2700 are in their fully closed positions as shown. In at least oneexample, the longitudinal length LL₁ of the proximal end portion 2642and the longitudinal length LL_(A) of the proximal second jaw opening2737 are approximately equal. Likewise, the first proximal jaw opening2656 is in vertical registration with the second jaw stiffener feature2734 when the jaws are in the fully closed positions. The longitudinallength LL₂ of the proximal first jaw opening 2656 is approximately equalto the longitudinal length LL_(B) of the second jaw stiffener feature2734. The first jaw stiffener feature 2650 is in vertical registrationwith the second jaw opening 2736. The longitudinal length LL₃ of thefirst jaw stiffener feature 2650 is approximately equal to thelongitudinal length LL_(C) of the second jaw opening 2736. The secondjaw stiffener feature 2735 is in vertical registration with the firstjaw opening 2654. The longitudinal length LL_(D) of the second jawstiffener feature 2735 is approximately equal to the longitudinal lengthLL₄ of the first jaw opening 2654. The first jaw stiffener feature 2652is in vertical registration with the second jaw opening 2738. Thelongitudinal length LL₅ of the first jaw stiffener feature 2652 isapproximately equal to the longitudinal length LL_(E) of the second jawopening 2738. The distal-most first jaw opening 2658 is in verticalregistration with the distal end portion 2726 of the second jaw 2700that extends from the distal-most fastener location A₂ to the second jawopening 2738. The longitudinal length of the distal first jaw openingLL₆ is approximately equal to the longitudinal length LL_(F) of thedistal end portion 2726.

In the illustrated example, the first jaw stiffener features 2650, 2652,as well as the proximal end portion 2642 and distal end portion 2644 ofthe first jaw 2610, extend transversely to the longitudinal axis betweenthe first and second lateral side portions 2634 and 2636 and have anarcuate cross-sectional shape. The first jaw stiffener features 2650,2652, as well as the proximal end portion 2642 and distal end portion2644 of the first jaw 2610, may also be referred to as “stiffenerbridges”. Likewise the second jaw stiffener features 2734, 2735 as wellas the proximal end portion 2725 and distal end portion 2726 of thesecond jaw 2700 extend transversely to the longitudinal axis LA betweenthe primary and secondary lateral side portions 2727 and 2728 and havean arcuate cross-sectional shape. The second jaw stiffener features2734, 2735, as well as the proximal end portion 2725 and distal endportion 2726 of the second jaw 2700 may also be referred to as“stiffener bridges”.

FIG. 62 illustrates a position of the dynamic clamping assembly 550 in afiring or ready to fire position. As can be seen in that Figure, aportion of the dynamic clamping assembly 550 may be viewed by theclinician through the proximal second jaw opening 2737. In FIG. 63, thedynamic clamping assembly 550 has been distally advanced and, when inthat position, the clinician may view the position of the dynamicclamping assembly 550 through the first jaw opening 2654 as well as thesecond jaw opening 2736. FIG. 64 illustrates the position of the dynamicclamping assembly 550 in its final or ending position wherein thedistal-most staples have been fired. As can be seen in that Figure, theposition of the dynamic clamping assembly 550 is viewable through thefirst jaw opening 2658. Thus, by longitudinally staggering the positionsof the first and second jaw stiffener features as well as the first andsecond jaw openings in the above-described manner, such arrangementserves to maintain a stiffness of the end effector 2500 and moreparticularly the tool assembly 2600 of the end effector 2500 and evenmore particularly the first and second jaws 2610, 2700 thereof when thefirst and second jaws are in their fully closed or clamped positions andthe dynamic clamping assembly 550 is distally advanced to cut theclamped tissue and fire the staples supported in the cartridge assembly.In addition, such arrangement enables the clinician to observe aposition of the dynamic clamping assembly 550 at any position during afiring stroke of the dynamic clamping assembly 550. As used in thiscontext, the “firing stroke” means the range of movement of the dynamicclamping assembly 550 from a firing position FP or ready to fireposition prior to firing any staples to an ending firing positionwherein all of the staples have been fired thereby. Alternativearrangements are contemplated wherein additional stiffening features andjaw openings are employed in the above-described manner in the first andsecond jaws. Still other arrangements are contemplated wherein only oneof the first and second jaws include the spaced stiffener features thatpermit the user to monitor the movement of the dynamic clamping assembly(firing member).

FIG. 65 illustrates a conventional dynamic clamping assembly 550applying clamping forces to an anvil assembly 612 which may lead to theundesirable deflection of the ledges 624 on the anvil plate 620 by theanvil engagement features 557 as well as the deflection of channelledges formed in the channel 720 by the channel engagement features 559.Unlike end effectors which employ a secondary jaw closure system, sucharrangement that employs the dynamic clamping assembly to apply allclosure forces to the first and second jaws. Such design relies, forexample, on very high local rolling forces to cause tissue compressionand establish a proper tissue gap between the jaws. Separate andindependent closure and firing systems, to the contrary, rely onprojection of force as distal as possible.

FIG. 66 illustrates a portion of an anvil assembly 2800 that comprisesan anvil plate 2810 that includes a staple forming undersurface 2812thereon. The anvil plate 2810 includes an elongate slot 2814 that isconfigured to accommodate the body portion of a dynamic clampingassembly 550 as the dynamic clamping assembly is axially advanced duringthe firing process. The elongate slot 2814 is defined between two anvilplate ledges 2816 that extend along each lateral side of the slot 2814.As a dynamic clamping member is distally advanced, anvil engagement tabsor pins on the dynamic clamping assembly 550 slidably engage the anvilplate ledges 2816 to retain the anvil assembly 2800 clamped onto thetarget tissue. An anvil cover plate or an anvil cap 2820 is received oncap ledges 2818 on the anvil plate 2810 and may be welded or otherwiseattached thereto. Each of the anvil plate ledges 2816 extends inwardlyin a cantilever configuration and has a ledge width LW. As the dynamicclamping assembly 550 clampingly engages the anvil assembly 2800, theanvil engagement features or tabs 556 of the dynamic clamping assembly550 engage the ledges 2816 to apply the closing motions thereto. In thisarrangement, however, the ledges 2816 are more robust and have a ledgethickness LT that is greater than the ledge thickness of the ledges onan anvil plate 620, for example.

FIG. 67 illustrates another anvil assembly 2900 that comprises an anvilplate 2910 that includes a staple forming undersurface 2912 thereon. Theanvil plate 2910 includes an elongate slot 2914 that is configured toaccommodate the body portion of a dynamic clamping assembly 550 as thedynamic clamping assembly is axially advanced during the firing process.The elongate slot 2914 is defined between two anvil plate ledges 2916that extend along each lateral side of the slot 2914. An anvil coverplate or an anvil cap 2920 is received on ledges 2918 on the anvil plate2910 and may be welded or otherwise attached thereto. Each of the anvilplate ledges 2916 extend inwardly in a cantilever configuration.Although each ledge 2916 has a ledge thickness LT′ that is less than theledge thickness LT (FIG. 66), each ledge 2916 has a ledge width LW′ thatis less than the ledge width LW of ledges 2816. Such shorter ledges 2916will experience less deflection that the ledges on the anvil plate 620,for example. Such arrangement represents an improvement over past anvilplate arrangements because the ledges 2916 are shorter which may limitthe amount of deflection experienced during the high load advancement ofthe dynamic clamping assembly.

As discussed above, in one example, the surgical end effector 500comprises a loading unit 510 that is configured to be operably coupledto a distal end of a shaft assembly of an adapter. As can be seen inFIGS. 68-70, in one arrangement the loading unit 510 comprises aproximal body portion 520 and a tool assembly 600 that is configured tobe articulated relative to the proximal body portion 520. When theproximal body portion 520 is coupled to the shaft assembly, the proximalbody portion 520 is axially aligned with a longitudinal axis LA that isdefined by the shaft assembly of the adapter. When the tool assembly 600is in an unarticulated position (FIG. 68), an axis TA of the toolassembly 600 is aligned with the longitudinal axis LA of the adaptershaft assembly, for example. The tool assembly 600 may also bearticulated to a first side (FIG. 69) wherein the tool axis TA istransverse to the longitudinal axis LA as well as to a second side (FIG.70) wherein the tool axis TA is transverse to the longitudinal axis LA.During some articulation motions, an articulation bar 258 of the adaptermay encounter significant resistive forces. Sensing the resisting forceson the articulation frame or articulation bar 258 which isinterconnected to an articulation link 560 of the DLU or MLU via astrain gauge or other deflection oriented circuit would enable thecontrol circuit for the articulation motor to back drive thearticulation motor when the force exceeds a predetermined threshold.Such action would remove some or all of the resistance provided to thearticulation frame via the drive member of the adapter and therebyprevent internal drive damage and/or minimize collateral tissue damage.FIG. 72 illustrates use of multi-axis strain gauges 310, 312 on theouter tube assembly 206. The multi-axis strain gauges 310, 312 areconnected to the circuit board 294 located within the inner housingassembly 204 (shown in FIG. 6). The strain gauges may, in thealternative, be mounted on the articulation bar 258. In at least onearrangement, for example, the strain goes negative as the force on thearticulation bar 258 increases. Such arrangement may be particularlyuseful when the user intended to straighten the tool assembly (FIG. 68)to pull it back through a trocar, but failed to get the tool assembly600 fully straightened. In such case, the end effector may become jammedwithin the trocar cannula and/or result in high loading of thearticulation frame or articulation bar 258 and drive shaft 214. Thiscondition might be completely mitigated if the articulation system couldsense this condition via load on the articulation bar 258 or drive screw214 and longitudinally adjust the position of the articulation bar 258by energizing the articulation motor of the surgical instrument 100 towhich the adapter is attached until the bending forces are below thepredetermined threshold.

Articulation of the end effector 500 or, more particularly, thearticulation of the tool assembly 600 of the end effector 500 iscontrolled by rotating the second proximal drive shaft 214 that is inthreaded engagement with the articulation bearing assembly 252 as wasdiscussed above. See FIGS. 6-9. The second drive converting assembly 250of adapter 200 further includes articulation bar 258 that has a proximalportion that is secured to inner race 257 of articulation bearing 255.See FIG. 7. A distal portion of articulation bar 258 includes a slot 258a therein, which is configured to accept a hook 562 of the articulationlink 560 (FIG. 10) of end effector 500. Articulation bar 258 functionsas a force transmitting member to components of end effector 500. In theillustrated arrangement and as further discussed in WO 2016/057225 A1,articulation bearing assembly 252 is both rotatable and longitudinallytranslatable and is configured to permit free, unimpeded rotationalmovement of the tool assembly 600 of the end effector 500 when its jawmembers 610, 700 are in an approximated position and/or when jaw members610, 700 are articulated.

In operation, as second proximal drive shaft 214 is rotated due to arotation of second connector sleeve 222, as a result of the rotation ofthe second coupling shaft 64 c of surgical instrument 100, articulationbearing assembly 252 is translated axially along threaded distal endportion 214 a of second proximal drive shaft 214. This axial translationof the articulation bearing assembly 252 causes the articulation bar 258to be axially translated relative to outer tube 206. As articulation bar258 is translated axially, it causes concomitant axial translation ofarticulation link 560 of end effector 500 to effectuate an articulationof tool assembly 600. Articulation bar 258 is secured to inner race 257of articulation bearing 253 and is thus free to rotate about thelongitudinal axis relative to outer race 259 of articulation bearing253.

It may be desirable to control the articulation of the end effector andto monitor the articulated position thereof during a surgical procedure.FIGS. 73-75 illustrate an improved articulation control system or seconddrive converting assembly 3250. The second drive converting assembly3250 in many aspects is identical to the second drive convertingassembly 250 described above, except for the specific differencesdiscussed below. As can be seen in FIG. 73, the second drive convertingassembly 3250 includes second proximal drive shaft 3214 that isrotatably supported within inner housing assembly 204 (shown in FIG. 6).Second rotatable proximal drive shaft 3214 includes a non-circular orshaped proximal end portion 3215 that is configured for connection withsecond coupling shaft 64 c of surgical instrument 100. Second rotatableproximal drive shaft 3214 further includes a threaded distal end portion3214 a that is configured to threadably engage an articulation bearinghousing 3253 of an articulation bearing assembly 3252. Housing 3253supports an articulation bearing 255 that has an inner race 257 that isindependently rotatable relative to an outer race 259. Articulationbearing housing 3253 has a non-circular outer profile, for exampletear-dropped shaped, that is slidably and non-rotatably disposed withina complementary bore (not shown) of inner housing hub 204 a (FIG. 6).Second drive converting assembly 3250 further includes articulation bar3258 that has a proximal portion that is secured to inner race 257 ofarticulation bearing 255. A distal portion of articulation bar 3258includes a slot 3258 a therein, which is configured to accept a hook 562of the articulation link 560 (FIG. 10) of end effector 500. Articulationbar 3258 functions as a force transmitting member to components of endeffector 500.

In the illustrated arrangement, the articulation bearing housing 3253 isin threaded engagement with the threaded distal end portion 3214 a ofthe second rotatable proximal drive shaft 3214. The bearing housing 3253may also be referred to herein as an articulation driver arrangement. Inat least one example, the bearing housing or articulation driverarrangement 3252 is configured to move axially in two directions from acentral or neutral position (FIG. 73) to a proximal axial position (FIG.74) and to a distal axial position (FIG. 75). When the bearing housing3253 is in the central or neutral position, the tool assembly 600 isaxially aligned with the proximal body portion 520 such that the toolassembly axis TA is aligned with the longitudinal axis LA (FIG. 68).Stated another way, the tool assembly or surgical end effector isunarticulated. The tool assembly 600 is oriented in the unarticulatedposition initially to facilitate insertion of the end effector through atrocar cannula. When the second rotatable proximal drive shaft 3214 isrotated in a first rotary direction, the bearing housing 3252 is drivenin a proximal axial direction from the neutral position. As the bearinghousing 3252 moves in the proximal direction PD, the tool assembly 600articulates in a first articulation direction AD₁ until the bearinghousing 3252 reaches the proximal axial position (FIG. 74) at whichpoint the tool assembly 600 is fully articulated in the articulationdirection AD₁ shown in FIG. 69, for example. When the second rotatableproximal drive shaft 3214 is rotated in a second rotary direction(opposite the first rotary direction), the bearing housing 3253 isdriven in a distal direction DD from the neutral position. As thebearing housing 3253 moves in the distal direction DD, the tool assembly600 articulates in a second articulation direction AD₂ until the bearinghousing 3253 reaches the distal axial position (FIG. 75) at which pointthe tool assembly 600 is fully articulated in the articulation directionAD₂ shown in FIG. 70, for example.

As discussed above, to insert the surgical end effector into the patientthrough a cannula of a trocar, the tool assembly may need to be in theunarticulated position and it may need to be returned to theunarticulated position to enable the surgical end effector to be removedfrom the patient through the trocar cannula after the procedure iscompleted. Thus, the articulation control system may need to be able toprecisely control the axial position of the bearing housing to ensurethat the tool assembly is precisely aligned with the proximal housing toavoid possible jamming of the end effector with the trocar cannula. Inone example, an articulation sensor assembly, generally indicated as3300 is employed to communicate with a motor controller circuit board142 a (FIG. 4), or other controller arrangement of the electromechanicalsurgical instrument 100 to which the adapter is operably coupled. In theillustrated example, the articulation sensor assembly 3300 comprises aproximal sensor 3310 and a distal sensor 3320 that are mounted to asensor bracket 3302. In addition, the bearing housing 3253 includes asensor magnet 3330 as can be seen in FIG. 73. The proximal and distalsensors 3310, 3320 may comprise conventional Hall sensors and be wiredto the adapter circuit board 294 (FIG. 6) for ultimate electricalcommunication with the motor controller circuit board 142 a in theelectromechanical surgical instrument 100 (FIG. 4). The sensors 3310,3320 serve to detect the position of the sensor magnet 3330 so as tomonitor when the bearing housing 3253 nears the neutral position andreaches the neutral position and convey that information back to themotor controller circuit board. Such arrangement enables a motorcontroller algorithm to vary the speed of the articulation motor as itapproaches the neutral position to allow the user to stop near theneutral position without the system intentionally pausing at thatpredetermined position.

In addition to the above described articulation sensor assembly, anO-ring 3340 or similar feature is located on the threaded portion 3214 aof the second rotatable proximal drive shaft 3214 in place of or oversome of the threads of the threaded portion 3214 a. In such anarrangement, a spike in the articulation motor current (e.g., motor156—FIG. 4) will occur when the O-ring 3340 encounters a threadedportion 3350 of the bearing housing 3253. This current spike will occurwhen the O-ring 3340 encounters the threads 3350 to increase rotaryresistance or friction when entering from a proximal direction or adistal direction of travel and is used to determine the distance thatthe bearing housing 3253 is from the neutral position. Once a spike inmotor current is detected, an algorithm controlling the articulationmotor 156 sets the drive screw rotary position to zero and thearticulation motor 156 then rotates the drive screw 3214 in the properrotary direction to drive the bearing housing 3253 axially to reach theneutral position. In alternative arrangements of the O-ring, selectthreads of the threaded portion 3214 a may be removed or omitted orintentionally damaged or altered to alter the rotationalresistance/friction and thus alter the amount of motor current drawn bythe articulation motor to facilitate control of the articulation motorin the above-described manner.

FIGS. 76 and 77 depict an alternative proximal drive shaft 3414 that maybe employed to axially advance the bearing housing 3253 and detect theposition of the bearing housing 3253 as the drive shaft 3414 is rotatedin the first and second rotary directions. As can be seen in FIGS. 76and 77, the proximal drive shaft 3414 is formed with a proximal set ofthreads 3420, a distal set of threads 3430 and a center thread 3440. Thecenter thread 3440 is centrally located between the proximal set ofthreads 3420 and the distal set of threads 3430 and is separatedtherefrom by unthreaded portions 3450. Threads 3420, 3430, 3440 areconfigured to threadably engage internal threads 3350 formed in thebearing housing 3253. FIG. 76 illustrates the bearing housing 3253 inthe neutral position. As can be seen in FIG. 76, the least mount ofthreads (including the threads of the proximal thread segment 3420, thedistal thread segment 3430 and the center thread 3430) are in threadedcontact with the threads 3350 of the bearing housing 3253 and will thusresult in the lowest amount of current drawn by the articulation motor.FIG. 77 illustrates the bearing housing 3253 being moved in the proximaldirection with all of the threads of the proximal thread segment 3420 inthreaded engagement with the threads in the bearing housing 3253 whichwill cause the articulation motor 156 to experience a higher amount ofcurrent. Such higher current will also be experienced when the bearinghousing 3253 is driven in the distal direction DD. By monitoring whenthe current is at its lowest magnitude or is approaching the lowestmagnitude, an algorithm controlling the articulation motor 156 may beused to slow down and stop the articulation motor 156 in the variousmanners described herein.

FIGS. 78 and 79 depict an alternative proximal drive shaft 3514 andswitch arrangement 3550 that may be employed to detect when the bearinghousing 3253 approaches and reaches the neutral position as the driveshaft 3514 is rotated in the first and second rotary directions. As canbe seen in FIGS. 78 and 79, the proximal drive shaft 3514 is formed witha proximal set of threads 3520 and a distal set of threads 3530 that areseparated by an unthreaded central portion 3540 that has a diameter thatdecreases or tapers from each end so that it is smallest in its center.Threads 3520, 3530 are configured to threadably engage internal threads3350 formed in the bearing housing 3253. In this arrangement, the switcharrangement 3550 comprises a radially movable switch plunger 3552 thatis supported in the bearing housing 3253 and is biased into contact thedrive shaft 3514 by a biasing member such as a spring 3554. The switchplunger 3552 includes contacts 3556 that are configured to operablyinterface with contacts 3558 in the bearing housing 3253. FIG. 78illustrates the bearing housing 3253 in the neutral position. As can beseen in FIG. 78, the switch plunger 3552 is in contact withapproximately the center of the unthreaded central portion 3540 of thedrive shaft 3514 such that the contacts 3556 are in contact with thecontacts 3558. Contacts 3556/3558 communicate with the motor controlcircuit in the surgical instrument 100 through the circuit board 294 toindicate that the bearing housing 3253 is in the neutral position. FIG.79 illustrates the bearing housing 3253 being moved in the proximaldirection PD with all of the threads of the proximal thread segment 3520in threaded engagement with the threads in the bearing housing 3253 andthe switch plunger 3552 in contact with the proximal thread segment 3520which moves the contacts 3556 away from contacts 3558 as shown. Thiscondition will also occur when the bearing housing 3253 is moved in thedistal direction. Such arrangements may be employed to control thearticulation motor in the above-described manners.

FIGS. 80-83 depict an alternative switch arrangement 3650 for detectingwhen the bearing housing 3553 is in the neutral position. In thisarrangement for example, the switch arrangement 3650 is supported in theinner housing 204 and includes a radially movable switch plunger 3652.As can be seen in FIGS. 80-83, the bearing housing 3553 is formed withan activator detent 3555 that is configured to interact with the switchplunger 3652. The switch plunger 3652 interacts with a leaf spring 3654that is configured to engage a contact 3658 in the inner housing 204.FIG. 81 illustrates the bearing housing 3553 in a neutral position. Whenin that position, the switch plunger 3652 has biased the leaf spring3654 into contact with the contact 3658 to complete a circuit to informthe motor controller circuit through the circuit board 294 that thebearing housing 3553 is in the neutral position. FIG. 82 illustrates thebearing housing 3553 in a position that is proximal to the neutralposition such that the detent 3555 on the bearing housing 3553 isproximal to the center of the switch plunger 3652 to enable the spring3654 to move out of contact with the contact 3658. FIG. 83 illustratesthe bearing housing 3553 in a position distal to the neutral positionsuch that the detent 3555 on the bearing housing 3553 is distal to thecenter of the switch plunger 3652 to enable the leaf spring 3654 to moveout of contact with the contact 3658. Such arrangements may be employedto control the articulation motor 158 in the above-described manners.

As described above, in at least some examples, the adapter 200 employs aproximal rotary drive shaft 216 that is ultimately rotated by acorresponding motor in the surgical instrument 100 to rotate the shaftassembly about the longitudinal axis LA. During a procedure, it isdesirable for the clinician to know the exact rotary position of theshaft assembly for adjustment purposes and resetting purposes. Onearrangement, for example, could employ an optical detector arrangementfor detecting incremental etched or printed markings on the outer shafttube 206, for example. Such markings may be provided completely around aproximal end portion of the outer tube 206 that allow for detection andindication of multiple 360 increments. Longitudinal marks may correlatewith a ring advancing feature that moves one increment distal for eachfull 360° rotation.

FIG. 84 illustrates another rotational detection system 3750 that may beemployed to detect and control the rotation of the shaft assembly aboutthe longitudinal axis LA. As can be seen in that Figure, the rotationaldetection system 3750 includes a pair of rotational sensors 3752, 3754that are configured to sense the position of a sensor magnet 3756 in oneof the opposed, radially extending protrusions 266 b. The sensors 3752,3754 are below the centerline of the adapter. In another arrangement,one rotational sensor is employed and a sensor magnet is mounted in eachof the protrusions 266 b. The magnets are oriented so their polaritiesare different. Due to the different polarities, a single sensor is ableto detect the positions of both magnets ensuring unique tracking of eachmagnet and proper determination of position. This information istransmitted to the motor controller circuit in the surgical instrument100 through circuit board 294 and contacts 292. A control algorithm maybe employed to control the second motor 154 such that the rotation ofthe shaft assembly may be limited to rotate through a certain range orstop at a certain point or to bring the rotations induced within thelast use back to a zero position. In other examples, multiple 360°rotation overall limiting features which allow the shaft to turn apredetermined number of 360° rotations before instructing the user tocounter rotate. In other arrangements, the system may automaticallycause the motor to counter rotate the shaft assembly after the firstclosure cycle after the cartridge is reloaded or the DLU is replaced.

FIGS. 85-88 illustrate an end effector 4500 that may be used inconnection with the various adapter arrangements described herein. In onarrangement, the end effector 4500 comprises a first jaw 4610 in theform of an anvil assembly 4612. The anvil assembly 4612 comprises aproximal end portion 4614 and a distal end portion 4616 that define afirst longitudinal jaw axis or an anvil axis AA. The anvil assembly 4612further comprises a first jaw surface or anvil surface 4618 that mayinclude staple forming pockets (not shown) therein. In at least onearrangement, the anvil surface 4618 is approximately parallel to theanvil axis AA.

Still referring to FIGS. 85-88, the end effector 4500 further comprise asecond jaw 4700 that comprises a cartridge assembly 4701. In at leastone example, the cartridge assembly 4701 comprises a channel 4720 thatis configured to operably support a staple cartridge 4702 therein. Thechannel 4720 comprises a proximal channel end portion 4722 and a distalchannel end portion 4724 that defines a second longitudinal jaw axis orlongitudinal channel axis CA. The proximal end portion 4722 is pivotallypinned or otherwise pivotally coupled to the proximal end portion 4614of the anvil assembly 4612. The staple cartridge 4702 comprises acartridge proximal end portion 4704 and a cartridge distal end portion4706 and includes a cartridge deck surface 4708 that faces the anvilsurface 4618. The cartridge assembly 4701 and anvil assembly 4612 areselectively pivotable between a fully open position shown in FIG. 85 toa closed position (FIG. 86) to a fully closed position (FIG. 87) by adynamic clamping assembly 4550.

FIGS. 85-88 illustrate one form of a dynamic clamping assembly 4550 thatcomprises a vertical body portion 4552 that has a tissue cutting surface4554 formed thereon or attached thereto. An anvil engagement feature4556 is formed on one end of the body portion 4552 and comprises ananvil engagement tab 4557 that protrudes from each lateral side of thebody portion 4552. Similarly, a channel engagement feature 4558 isformed on the other end of the of the body portion 4552 and comprises achannel engagement tab 4559 that protrudes from each lateral side of thebody portion 4552. As can be seen in FIG. 88, the body portion 4552 isattached to or formed at a distal end of a flexible drive beam 4542 thatis operated in the various manners described above.

FIG. 85 illustrates the jaws 4610, 4700 in a fully open position. Whenin that position, the dynamic clamping assembly 4550 is in a parkingarea 4580 defined adjacent the proximal end portion 4704 of thecartridge assembly 4701 as well as the proximal channel end portion 4722and the proximal end portion 4614 of the anvil assembly 4612. When in astarting position in the parking area 4580, the channel engagementfeatures 4758 may not engage the channel and the anvil engagementfeatures may not engage the anvil assembly 4612. The anvil assembly 4612is formed with a pair of longitudinally extending anvil ledges 4620 thatare spaced from each other by an elongate anvil slot (not shown) that isconfigured to receive a portion of the body portion 4552 of the dynamicclamping assembly 4550 to extend therethrough. The anvil ledges 4620 areconfigured to be slidably engaged by the anvil engagement tabs 4557 onthe dynamic clamping assembly 4550 as the dynamic clamping assembly 4550is driven in the distal direction DD through the end effector 4500.Likewise, the proximal channel end portion 4722 comprises a cam surfaceor ramp arrangement 4730 that is configured to be initially engaged bythe channel engagement tabs 4559 on the dynamic clamping assembly 4550as the dynamic clamping assembly 4550 is initially moved distally fromthe starting position. The channel 4720 is formed with a pair oflongitudinally extending channel ledges 4732 that are configured to beslidably engaged by the channel engagement tabs 4559 as the dynamicclamping assembly is driven from the starting position to endingposition.

In one arrangement, the cam surface arrangement 4730 is configured suchthat upon initial engagement of the channel engagement tabs 4559therewith, the cartridge assembly 4701 and anvil assembly 4612 arepivoted to a fully closed position wherein the cartridge distal endportion 4706 actually contacts the distal end portion 4616 of the anvilassembly 4612. Such arrangement may be useful when manipulating thetarget tissue and/or adjacent tissue prior to clamping the target tissuebetween the jaws. The clinician can move the dynamic clamping assemblyto the initial closure position wherein the cam surface arrangement 4730is initially engaged by the channel engagement tabs 4559 to bring thedistal end portions 4706 and 4616 together to grasp and manipulatetissue.

Once the target tissue has been located between the anvil surface 4618and the cartridge deck surface 4708, the dynamic clamping assembly ismoved distally through the surgical end effector 4500. As the dynamicclamping assembly 4550 moves distally, the clamped tissue applies anopening force or forces to the anvil 4612 and cartridge assembly 4701which must be overcome by the dynamic clamping assembly 4550 as it movesdistally. These forces increase the amounts of frictional forces thatare generated between the anvil engagement tabs 4557 and the anvilledges 4620 and the channel engagement tabs 4559 and the channel ledges4732. In one arrangement, as can be seen in FIG. 85, the channel ledges4732 each include an upper ledge surface 4733 that is engaged by acorresponding one of the channel engagement tabs 4559. The channelledges 4732 are oriented at an angle such that a proximal end 4735 ofeach of the channel ledges 4732 is spaced from the cartridge decksurface 4708 a first distance D₁ and a distal end 4737 of each of thechannel ledges 4732 is spaced from the cartridge deck surface 4708 asecond distance D₂ wherein D₂>D₁. FIG. 86 illustrates the jaws 4600,4700 in a closed position wherein the distal end 4706 of the cartridge4702 is still spaced from the distal end 4616 of the anvil assembly 4612(the cartridge deck surface 4708 and the anvil surface 4618 are spacedfrom each other, but approximately parallel to each other). When in thatposition, the upper ledge surface 4733 is angled (approximately0.5°-2.0°, for example) relative to a longitudinal axis LA. FIGS. 87 and88 illustrate the jaws 4610, 4700 in a fully closed position (the distalend 4706 of the cartridge 4702 is in contact with the distal end 4616 ofthe anvil assembly 4612). When in that configuration, the upper ledgesurface 4733 is approximately parallel to the longitudinal axis LA. Sucharrangement can reduce the amount of frictional resistance experiencedby the dynamic clamping assembly 4550 as the dynamic clamping assembly4550 is driven distally (direction DD) through a firing stroke whereinthe dynamic clamping assembly 4550 not only retains the jaws 4600, 4700clamped onto the target tissue, but cuts the target tissue and fires thestaples operably supported in the staple cartridge 4702 through the cuttissue.

FIG. 89 illustrates a surgical end effector 7500 that comprises aportion of an adapter 7200 that is configured to be used in connectionwith an electromechanical surgical instrument 100, for example. In theillustrated arrangement, the surgical end effector 7500 comprises aloading unit 7510. The loading unit 7510 comprises a proximal bodyportion 7520 and a tool assembly 7600. Tool assembly 7600 includes apair of jaw members including a first jaw 7610 that comprises an anvilassembly 7612 and a second jaw 7700 that comprises a cartridge assembly7701. One jaw member is pivotal in relation to the other to enable theclamping of tissue between the jaw members. The cartridge assembly 7701is movable in relation to anvil assembly 7612 and is movable between anopen or unclamped position and a closed or approximated position.However, the anvil assembly 7612, or both the cartridge assembly 7701and the anvil assembly 7612, can be movable.

The cartridge assembly 7701 is identical to cartridge assembly 701described in detail above. The loading unit 7510 includes a dynamicclamping assembly 550 that is attached to or formed at the distal end ofthe flexible drive beam 542. The dynamic clamping assembly 550 includesa vertical body portion 552 that has a tissue cutting surface 554 formedthereon or attached thereto. An anvil engagement feature 556 is formedon one end of the body portion 552 and comprises an anvil engagement tab557 that protrudes from each lateral side of the body portion 552.Similarly, a channel engagement feature 558 is formed on the other endof the of the body portion 552 and comprises a channel engagement tab559 that protrudes from each lateral side of the body portion 552. Asindicated above, the flexible drive beam 542 interfaces with a hollowdrive member 548 (FIG. 10) that is configured to be attached to anaxially movable firing member or distal drive member 248 (FIG. 6) of theadapter 7200 to which it is attached. As was also described above, thedistal drive member 248 is configured to be axially advanced in thedistal and proximal directions when the proximal drive shaft 212 isrotated. In particular, a threaded portion 212 b is configured tothreadably engage a drive coupling nut 244 that is attached to thedistal drive member 248. The drive coupling nut 244 is slidably receivedin a mounting bushing 299 that enables the drive coupling nut 244 tomove axially, but prevents the drive coupling nut 244 from rotating.Proximal drive shaft 212 is configured to receive rotary motions from asource of rotary motions (motor 152, for example) in theelectromechanical surgical instrument 100 (see FIG. 4). Actuation ofmotor 152 will result in the rotation of the proximal drive shaft 212and the axial displacement of the distal drive member 248 when theadapter 7200 is coupled to the electromechanical surgical instrument100. As was also discussed above, the motor 152 is part of a power-packcore assembly 106 and is electrically connected to controller circuitboard 142 and battery 144. See FIG. 4.

Turning again to FIG. 89, the dynamic clamping assembly 550 isconfigured to axially move through the first and second jaws through afiring stroke FS that extends from a starting position SP of the dynamicclamping assembly 550 to an ending position EP of the dynamic clampingassembly 550. When the dynamic clamping assembly 550 is located in thestarting position (shown in solid lines in FIG. 89), the jaws 7610, 7700would be in their fully open position. However, to illustrate the firingstroke portions, FIG. 89 illustrates the jaws 7610 and 7700 in a closedposition. When the dynamic clamping assembly 550 is axially advanced ina distal direction DD from the starting position through a proximalportion PFS_(A) of the firing stroke FS, the distal clamping assembly550 will move the jaws 7610, 7700 from the fully open position to aclosed position CP. As the distal clamping assembly 550 continues tomove distally from the closed position CP through a portion PFS_(B) ofthe firing stroke FS, the dynamic clamping assembly 550 retains the jaws7610, 7700 in the closed position, but it has not yet encountered tissuethat has been clamped between the jaws 7610, 7700. As can be seen inFIG. 89, for example, the first jaw 7610 includes upwardly extendingtissue stops 7646 that prevent tissue that is clamped between the jaws7610, 7700 from extending proximally beyond that point. Such point,designated as the firing point FP in FIG. 89, coincides with thelocations of the proximal most fasteners that are stored in the staplecartridge 702 that is mounted in the cartridge assembly 7701. Sucharrangement ensures that, when the cutting surface 554 on the dynamicclamping assembly first encounters the clamped tissue, the tissuesevered thereby will be stapled or fastened. As the dynamic clampingassembly 550 is driven distally from the firing point FP through anintermediate portion IFS of the firing stroke FS, the dynamic clampingassembly fires or causes a majority of the fasteners stored in thecartridge body 702 to be ejected therefrom into forming engagement withthe first jaw 7610. Further distal advancement of the dynamic clampingassembly through a distal portion DFS of the firing stroke FS willresult in the final cutting of the clamped tissue and ejection of theremaining fasteners associated with that portion of the firing stroke.

As the dynamic clamping assembly 550 is distally advanced through thefiring stroke FS, it may be useful to control the output of rotarymotions from the motor 152. For example, more power may be required toadvance the dynamic clamping assembly 550 through the intermediatefiring stroke portion IFS than is needed to advance the dynamic clampingassembly 550 through a proximal portion of the firing stroke PFS and adistal portion of the firing stroke DFS because of the additionalresistance encountered when cutting the clamped tissue and firing thefasteners therethrough. In addition, as the dynamic clamping assembly550 passes through the intermediate firing stroke IFS, the amount ofpower required after it passes through the midpoint of the intermediatefiring stroke portion may start to diminish because of the diminishingtissue resistance due to the migration of the fluids from that remainingportion of the clamped tissue, for example.

In the illustrated example, the end effector 7500 is configured for usein connection with adapter 7200. Adapter 7200 is identical to adapter200 except for the differences noted herein. In one arrangement, theadapter 7200 employs a means for determining when the dynamic clampingassembly 550 is axially located within the intermediate portion of thefiring stroke and communicating a signal indicative of that positionback to a control circuit for the motor 152 to control the output of themotor 152. In one form, the means for determining comprises a firingsystem sensor assembly generally designated as 7300. In the illustratedexample shown in FIGS. 90-93, the sensor assembly 7300 comprises a fixedsensor 7310 that is mounted within inner housing assembly 204 or outertube 206. The fixed sensor 7310 may comprise a Hall effect sensor thatis wired to or otherwise communicates with the electrical assembly 290(FIG. 6) which serves to allow for communication of correspondingsignals to a motor controller circuit of surgical instrument 100 thatcontrols the motor 152, for example.

Still referring to FIGS. 90-93 the sensor assembly 7300 furthercomprises a sensor actuator 7320 that is mounted on a sensor coupler arm7330 that movably interfaces with the drive coupling nut 244. In oneform, the sensor coupler arm 7330 includes a proximal support tab 7332upon which the sensor actuator 7320 is supported. In one arrangement,the sensor actuator 7320 comprises a magnet that is configured to bedetected by the Hall effect sensor 7310. The sensor coupler arm 7330further includes a distal mounting tab 7334 that is configured to beslidably received within an axial slot 7350 provided in the drivecoupling nut 244. The proximal support tab 7332 is biased into axialsensing alignment so that the sensor actuator 7320 may be sensed by thefixed sensor 7310. In the illustrated arrangement, for example, theproximal support tab 7332 is biased into axial sensing alignment by aproximal spring 7352 and a distal spring 7354 that are mounted withinthe inner housing assembly 204 or outer tube 206.

FIGS. 91-94 illustrate an actuation stroke of the drive coupling nut 244that corresponds to the firing stroke FS of the dynamic clampingassembly 550. FIG. 91 illustrates the position of the drive coupling nut244 when the dynamic clamping assembly 550 is in the starting position.As can be seen in that Figure, the drive coupling nut 244 has driven thesensor coupler arm 7330 proximally so that the sensor actuator 7320 isproximal to the fixed sensor 7310 and out of sensing alignmenttherewith. This starting position of the sensor actuator 7320 isdesignated as SSA in FIG. 94. As the rotary drive shaft 212 is initiallyrotated, the drive coupling nut 244 is axially driven in the distaldirection DD through a proximal portion PAS of the actuation stroke AS.The proximal portion PAS of the actuation stroke AS corresponds to theproximal portion PFS of the firing stroke FS of the dynamic clampingassembly 550. The drive coupling nut 244 is driven to an actuationfiring point AFP (FIG. 94) that corresponds with the firing point FP(FIG. 89) of the dynamic clamping assembly 550. As the drive couplingnut 244 approaches the actuation firing point AFP, the springs 7352 and7354 serve to move the sensor actuator 7320 into sensing alignment withthe fixed sensor 7310. As the drive coupling nut 244 is driven distallyfrom the actuation firing point AFP through an intermediate portion IASof the actuation stroke AS, the springs 7352, 7354 serve to bring thesensor actuator 7320 into sensing alignment with the fixed sensor 7310.After the drive coupling nut 244 moves distally through a first portionof the intermediate actuation stroke IAS₁ the springs 7352, 7354 serveto bias the sensor actuator 7320 into a sensor midpoint SMP thatcorresponds to the midpoint of the intermediate portion of the firingstroke FS of the dynamic clamping assembly 550. As the drive couplingnut 244 moves through the intermediate portion IAS of the actuationstroke, the springs 7352, 7354 bias the sensor actuator 7320 intosensing alignment with the fixed sensor 7310. Then signals indicative ofthe position of the dynamic clamping assembly may be transmitted by thefixed sensor 7310 to the motor control circuit as the drive nut 244moves through the entire intermediate actuation stroke portion IAS. FIG.92 illustrates a position of the drive nut 244 when in the intermediateportion of the actuation stroke. The fixed sensor 7310 and/or thesprings 7352, 7354 may be calibrated so that the fixed sensor 7310 sendssignals indicative of the specific position of the sensor actuator 7320as it passes through the first portion of the intermediate actuationstroke IAS₁ to the sensor midpoint SMP, so that the motor 152 may beappropriately controlled. For example, it may be desirable to start todecrease the power or current to the motor 152 as the sensor actuator7320 approaches the sensor midpoint SMP and then throughout a secondportion of the intermediate actuation stroke IAS₂ until the drive nut244 reaches the end of the intermediate actuation stroke IAS at whichpoint it begins a distal portion DAS of the actuation stroke whichcorresponds to the distal portion of the firing stroke DFS (FIG. 89).When the drive nut 244 reaches the actuator end point AEP whichcorresponds to the end point EP of the dynamic clamping assembly 550,the proximal tab 7344 of the sensor coupler arm 7330 is at the end ofthe slot 7350 in the drive nut 244 and the sensor actuator 7320 ispulled out of sensing alignment with the fixed senor 7310 as shown inFIG. 93. When in that position, power to the motor 152 has beencompletely stopped. The motor may then be operated to rotate the driveshaft 212 in an opposite direction to retract the dynamic clampingassembly 550 back to the starting position wherein the jaws are moved totheir fully open position. FIG. 95 is a graph that plots thedisplacement of the dynamic clamping assembly as measured by the sensorassembly 7300 verse the firing stroke distance of the dynamic clampingassembly for one example. +X is the distance traveled by the dynamicclamping assembly between the firing point FP and the midpoint of theintermediate portion of the firing stroke. This corresponds to thedistance that the sensor actuator 7320 travels between the startingposition SSA of the sensor actuator 7320 and the sensor midpoint SMP asshown in FIG. 94. −X is the distance traveled by the dynamic clampingassembly 550 between the midpoint of the intermediate portion of thefiring stroke and the end position EP. This corresponds to the distancethat the sensor actuator 7320 travels between the sensor midpoint SMPand a sensor end point SEP as shown in FIG. 94.

During use of an adapter 200 and electromechanical surgical instrument100, the surgical end effector 500 is generally positioned in anunarticulated position (the longitudinal axis defined by the proximalhousing portion is axially aligned with the longitudinal axis LA of theshaft assembly of the adapter) to permit the surgical end effector 500to be inserted through a trocar cannula into the patient. Once thesurgical end effector 500 has been inserted into the patient, theclinician may activate the source of rotary actuation motions (motor156) to apply an amount of rotary articulation motions to the rotaryarticulation drive shaft 214 in the adapter 200 to axially displace thearticulation driver or bar 258 an amount necessary to articulate thesurgical end effector 500 into a desired articulated position. Once thesurgical end effector 500 has been articulated in the desiredarticulated position, the motor 156 is deactivated so that the endeffector 500 remains articulated during the firing stroke.

After the surgical end effector 500 has been articulated into thedesired articulated position and the source of rotary articulationmotions has been deactivated in the electromechanical surgicalinstrument 100, the clinician activates the source of rotary firingmotions (motor 152) to apply an initial amount of rotary firing motionsto the rotary firing drive shaft 214 in the adapter 200 to axiallydisplace the distal drive member 248 to ultimately cause the dynamicclamping assembly 550 in the surgical end effector 500 to move from thestarting position to a firing position. As the dynamic clamping assembly550 moves from the starting position to the firing position, the dynamicclamping assembly applies a closing motion to the anvil assembly 612 andcartridge assembly 701 of the end effector 500 to move the anvil 612 andcartridge assembly 701 from a fully open position to a closed position.At that point, the clinician may cease actuation of the motor 152 ormotor 152 may continue to be actuated to drive the dynamic clampingassembly 550 through its firing stroke wherein it cuts the clampedtissue and causes the fasteners stored in the cartridge assembly 701 tobe ejected into forming engagement with the anvil 612. As the flexiblefiring beam 542 applies the axial firing motions from the distal drivemember 248 to the dynamic clamping assembly 550, the flexible firingbeam 542 must flex around the articulation joint to accommodate thearticulated position of tool assembly 600 relative to the proximal bodyportion 520. Such flexing of the firing beam 542 applies resistiveforces to the tool assembly 600 that seek to undesirably straighten oralign the tool assembly 600 with the proximal body portion 520 andessentially move the tool assembly 600 out of the desired articulatedposition. In at least one form, the adapter 8200 depicted in FIG. 96 mayaddress such problem.

FIG. 96 illustrates a portion of adapter 8200 which is otherwiseidentical to adapter 200 described above. As can be seen in that Figure,adapter 8200 includes a control system 8210 that operably interfaceswith the articulation driver 258 and is configured to communicateelectrical signals back to a motor control circuit for the motor 156that applies the rotary articulation motions in the electromechanicalsurgical instrument. In the illustrated arrangement, for example, thecontrol system 8210 includes a strain gauge 8212 that is or attached tothe articulation driver 258. Leads 8214 for the strain gauge extendthrough an opening 8218 in an internal bushing 8216 that may be mountedin the inner housing 204 to be coupled to a connector 8219 that mayinterface with a slip ring arrangement (not shown) that is in electricalcontact with the electrical assembly 290, for example. In sucharrangement, the leads 8214 are long enough to permit the shaft assembly203′ to rotate about the longitudinal axis LA. In an alternativearrangement, the leads 8214 are attached to a connector that issupported within the inner housing 204 and configured to electricalinterface with the slip ring 298 of the electrical assembly 290 (FIG.6). In such arrangement, the slip ring 298 is in electricalcommunication with a circuit board 294. The circuit board 294 includes aplurality of electrical contact blades 292 for electrical connection topass-through connector 66 of plate assembly 60 of shell housing 10 ofthe surgical instrument 100. Such arrangement facilitates passage ofsignals from the strain gauge 8212 to the motor controller circuit board142 a in the surgical instrument 100.

FIG. 97 illustrates the actions of one method 8220 for controllingvarious features of the adapter 8200 when operably coupled to thesurgical instrument 100 or other motor powered system after the surgicalend effector 500 of the adapter 8200 has been entered into the patient.When a trocar is employed, the surgical end effector 500 is in anunarticulated position with the jaws 610, 700 closed to enable thesurgical end effector 500 to pass through the cannula of the trocar.Once the surgical end effector 500 has entered the patient, the anvil612 and cartridge assembly 701 of the surgical end effector 500 areopened to the fully open position. This may be accomplished by reversingthe motor 152 (through manual controls or automatic controls) to movethe dynamic clamping assembly 550 back to its starting position.Thereafter, the end effector 500 is then articulated to a desiredarticulated position (action 8222). This is accomplished by actuatingthe source of rotary articulation motions (motor 156) in the surgicalinstrument 100 or other motor powered system (through manual controls orautomatic controls). In the example of FIG. 97, the clamping action 8224encompasses first opening the jaws (if the end effector was articulatedto the desired articulated position with the jaws closed) and thenclamping the jaws onto a target tissue. This is accomplished byreversing the motor 152 or other motor driven system (through manualcontrols or automatic controls) to move the dynamic clamping assembly550 back to its starting position (if the jaws were closed) and thenactuating the motor 152 (through manual controls or automatic controls)to move the dynamic clamping assembly 550 from its starting position toits firing position (action 8224).

Still referring to FIG. 97, once the target tissue has been clampedbetween the jaws (anvil assembly 612 and cartridge assembly 701) theaxial position of the articulation driver 258 may be recorded as well asthe amount of strain experienced by the articulation driver 258 isrecorded by the motor controller circuit (action 8226). Other means mayalso be employed to determine and record the articulated position of thesurgical end effector. In an alternative arrangement, the amount ofstrain experienced by the articulation driver may be recorded prior toclamping. Thereafter, the firing stroke is initiated (action 8228). Thismay be accomplished by actuating the motor 152 or other motor drivensystem (through manual controls or automatic controls) to move thedynamic clamping assembly 550 from its firing position to its endingposition within the end effector 500. As the dynamic clamping assembly550 moves from the firing position to ending position, the dynamicclamping assembly 550 cuts the clamped tissue and ejects the fastenersstored in the cartridge assembly into forming engagement with the anvil.During this firing stroke (action 8228), the magnitude and direction ofa change in the amount of strain experienced by the articulation driver258 is measured and sent to the motor control circuit (action 8230). Themotor control circuit compares this strain information to the previouslyrecorded strain information and if necessary, the motor 156 or othermotor driven system is reactivated (through manual controls or automaticcontrols) to move the articulation driver 258 in an appropriate axialdirection to bring the recorded strain approximately back to thepreviously recorded strain information or at least reduce the amount ofstrain being experienced by the articulation driver 258 as the dynamicclamping assembly 550 is being driven from the firing position to endingposition (action 8232) to maintain the surgical end effector in thedesired articulated position.

As was discussed above, the electromechanical surgical instrument 100includes the power-pack or the handle assembly 101 and an outer shellhousing 10 that is configured to selectively receive and substantiallyencase the handle assembly 101. A sterile barrier plate 60 is interposedbetween the handle assembly 101 and the outer shell housing tofacilitate operable coupling of rotatable motor drive shafts of themotors through the sterile barrier to the corresponding drive shafts ofan adapter coupled thereto. Rotation of the motor drive shafts thenfunction to drive shafts and/or gear components of adapter 200 in orderto perform the various operations of the surgical instrument 100. Duringoperation, it may be desirable to control the motors to adjust the rateof shaft rotation and/or the direction of shaft rotation based upon thelocation of the various components of the adapter 200 that is coupledthereto. For example, it may be desirable to control the rate ofrotation (and direction) of motor 152 and rotatable drive shaft 152 adepending upon the position of the dynamic clamping assembly 550 withinthe end effector. For example, when the dynamic clamping assembly 550 isnearing the end of its firing stroke, it may be useful to slow itsdistal advancement down so as to avoid slamming the dynamic clampingassembly and/or related components into the cartridge body at the end ofthe firing stroke. Further, there may be times during the firing strokewhen it may be useful to slow down the dynamic clamping assembly 550advancement or to speed it up. Similar conditions may also occur whichrelate to the operation of motors 154 and 156.

FIG. 98 illustrates a portion of a power pack core assembly 9106 andmotor control system 9180 that may be employed to control the operationof motors 152, 154, 156 and which is entirely located within the sterilebarrier or outer shell housing 10. Power pack core assembly 9106 issubstantially identical to power pack core assembly 106 described above,except for the differences discussed below. As can be seen in FIG. 98,each motor 152, 154, 156 is supported on a motor bracket 9148 that issimilar to motor bracket 148 described above. The motor bracket 9148rotatably supports three rotatable drive connector sleeves 152 b, 154 b,156 b that are keyed to respective motor shafts 152 a, 154 a, 156 a ofmotors 152, 154, 156. Drive connector sleeves 152 b, 154 b, 156 bnon-rotatably receive proximal ends of respective rotatable couplingshaft assemblies 9152 a, 9154 a, 9156 a of a plate assembly 9160.

Plate assembly 9160 is identical to plate assembly 60 except for thedifferences discussed below. For example, rotatable coupling shaftassembly 9152 a comprises a coupler bushing 9152 b that is rotatablysupported in a plate 9162 of plate assembly 9160. A coupler shaft 9152 cis non-rotatably coupled to said coupler bushing 9152 b. A proximal endof coupler shaft 9152 c extends proximally from the plate 9162 to bedrivingly engaged with the drive connector sleeve 152 b. A distal end ofcoupler shaft 9152 c is configured to extend through a correspondingaperture 22 b (FIG. 3) in connecting portion 20 of distal half-section10 a when sterile barrier plate assembly 9160 is disposed within shellcavity 10 c of shell housing 10. Rotatable coupling shaft assembly 9154a comprises a coupler bushing 9154 b that is rotatably supported inplate 9162. A coupler shaft 9154 c is non-rotatably coupled to saidcoupler bushing 9154 b. A proximal end of coupler shaft 9154 c extendsproximally from the plate 9162 to be drivingly engaged with the driveconnector sleeve 154 b. A distal end of coupler shaft 9154 c isconfigured to extend through a corresponding aperture 22 c (see FIG. 5)in connecting portion 20 of distal half-section 10 a when sterilebarrier plate assembly 9160 is disposed within shell cavity 10 c ofshell housing 10. Rotatable coupling shaft assembly 9156 a comprises acoupler bushing 9156 b that is rotatably supported in plate 9162. Acoupler shaft 9156 c is non-rotatably coupled to said coupler bushing9156 b. A proximal end of coupler shaft 9156 c extends proximally fromthe plate 9162 to be drivingly engaged with the drive connector sleeve156 b. A distal end of coupler shaft 9156 c is configured to extendthrough a corresponding aperture 22 a (FIG. 3) in connecting portion 20of distal half-section 10 a when sterile barrier plate assembly 9160 isdisposed within shell cavity 10 c of shell housing 10.

Still referring to FIG. 98, Drive connector sleeves 152 b, 154 b, 156 bare each spring biased away from respective motors 152, 154, 156 bycorresponding springs 9158 and washers 9159. Drive connector sleeve 152b serves to drivingly couple rotatable motor drive shaft 152 a to thecoupler shaft 9152 c. Drive connector sleeve 154 b serves to drivinglycouple rotatable motor drive shaft 154 a to the coupler shaft 9154 c.Drive connector sleeve 156 b serves to drivingly couple rotatable motordrive shaft 156 a to the coupler shaft 9156 c.

The motor control system 9180 includes a controller circuit board 142 aand battery 144 (FIG. 4) that are coupled to each motor 152, 154, 156.Each motor 152, 154, 156 is controlled by a respective motor controller.The motor controllers are disposed on motor controller circuit board 142a. In on example, the motor controllers comprise A3930/31K motor driversfrom Allegro Microsystems, Inc. The A3930/31K motor drivers are designedto control a 3-phase brushless DC (BLDC) motor with N-channel externalpower MOSFETs, such as the motors 152, 154, 156. Each of the motorcontrollers is coupled to a main controller disposed on the maincontroller circuit board 142 b. The main controller is also coupled tomemory, which is also disposed on the main controller circuit board 142b. In one example, the main controller comprises an ARM Cortex M4processor from Freescale Semiconductor, Inc. which includes 1024kilobytes of internal flash memory. The main controller communicateswith the motor controllers through an FPGA, which provides control logicsignals. The control logic of the motor controllers then outputscorresponding energization signals to their respective motors 152, 154,156 using fixed frequency pulse width modulation (PWM).

In the illustrated arrangement, the motor control system 9180 furthercomprises stationary sensors 9182, 9184, 9186 that are wired to orotherwise communicate with the main controller circuit board 142 band/or the motor controllers. For example, stationary sensor 9182 isassociated with motor 152 and is wired to or otherwise communicates withthe main controller circuit board 142 b and/or the motor controller formotor 152. Stationary sensor 9184 is associated with motor 154 and iswired to or otherwise communicates with the main controller circuitboard 142 b and/or the motor controller for motor 154. Stationary sensor9186 is associated with motor 156 and is wired to or otherwisecommunicates with the main controller circuit board 142 b and/or themotor controller for motor 156. In one example, sensors 9182, 9184, 9186comprise Hall effect sensors that are arranged to detect sensoractuators associated with coupler shafts 9152 c, 9154 c, 9156 c. Forexample, the coupler bushing 9152 b may be magnetized or support amagnet 9152 d therein. Coupler bushing 9154 b may be magnetized orsupport a magnet 9154 d therein. Coupler bushing 9156 b may bemagnetized or support a magnet 9156 d therein.

Actuation of motor 152 will result in the rotation of the drive couplershaft 9152 c and the accompanying magnet 9152 d. Sensor 9182 isconfigured to detect the rotary travel of magnet 9152 d and conveysignals indicative of such position to the motor controller or processorcontrolling motor 152. These signals may be used by thecontroller/processor to maintain, increase or reduce the rate ofrotation of the rotatable motor drive shaft 152 a depending upon thesignals. The processor may also change the direction of rotation of therotatable drive shaft 152 a. Actuation of motor 154 will result in therotation of the drive coupler shaft 9154 c and the accompanying magnet9154 d. Sensor 9184 is configured to detect the rotary travel of magnet9154 d and convey signals indicative of such position to the motorcontroller or processor controlling motor 154. These signals may be usedby the controller/processor to maintain, increase or reduce the rate ofrotation of the rotatable motor drive shaft 154 a depending upon thesignals. The processor may also change the direction of rotation of therotatable drive shaft 154 a. Actuation of motor 156 will result in therotation of the drive coupler shaft 9156 c and the accompanying magnet9156 d. Sensor 9186 is configured to detect the rotary travel of magnet9156 d and convey signals indicative of such position to the motorcontroller or processor controlling motor 156. These signals may be usedby the controller/processor to maintain, increase or reduce the rate ofrotation of the rotatable motor drive shaft 156 a depending upon thesignals. The processor may also change the direction of rotation of therotatable drive shaft 156 a.

FIGS. 99-101 illustrate an alternative motor control system 9200 forcontrolling the operation of motors 152, 154, 156. In this example, atleast one switch 9210 is associated with each of the rotatable motordrive shafts 152 a, 154 a, 156 a and is mounted in the motor bracket9248 which supports the motors 152, 154, 156. In the illustratedexample, four switches 9210 are circumferentially spaced around each ofthe rotatable drive shafts 152 a, 154 a, 156 a. FIG. 101 illustratessuch switch arrangement for rotatable motor drive shaft 152 a. Eachswitch 9210 is wired to or otherwise communicates with the maincontroller circuit board 142 b and/or the motor controller for thecorresponding motor 152, 154, 156. In one arrangement, each driveconnector sleeve has at least one switch actuator thereon. FIGS. 99-101illustrate drive connector sleeve 9220 which has four circumferentiallyspaced switch actuator nubs 9222 formed thereon for operable interactionwith the corresponding switches 9210. The drive connector sleeves 9220serve to operably couple the rotatable motor drive shafts 152 a, 154 a,156 a to their corresponding coupler shafts 9152 c, 9154 c, 9156 c. Asthe rotatable motor drive shafts 152 a, 154 a, 156 a rotate, the driveconnector sleeve 9220 that is non-rotatably connected thereto alsorotates causing the corresponding switch actuators 9222 to rotate intoand out of actuatable contact with the corresponding switches 9210 toconvey signals indicative of the rotary position of the correspondingdrive shaft 152 a, 154 a, 156 a to the motor controller or processorcontrolling that particular motor. These signals may be used by thecontroller/processor to maintain, increase or reduce the rate ofrotation of the rotatable motor drive shaft depending upon the signals.The processor may also change the direction of rotation of the rotatabledrive shaft.

The surgical instrument 100 can include sensor assemblies for detectingvarious states and/or parameters associated with the operation of thesurgical instrument 100. A control circuit or processor can monitorthese sensed states and/or parameters and then control the operation ofthe surgical instrument 100 accordingly. For example, the surgicalinstrument 100 can monitor the current drawn by the motor driving thefirst force/rotation transmitting/converting assembly 240 (FIG. 6) inorder to control the speed at which the clamping member 550 (FIG. 10) istranslated. As another example, the surgical instrument 100 can monitorthe gap or distance between the jaw members or the anvil plate 620 (FIG.10) and the cartridge body 702 (FIG. 10) when the end effector 500 isclamped in order to control the speed at which the clamping member 550is driven thereafter. These and other sensor assemblies withcorresponding logic executed by a control circuit or processor inconjunction with the sensor assemblies are described herein below.

FIGS. 102 and 103 illustrate schematic diagrams of a circuit 2000 forcontrolling a motor 2010 of a surgical instrument 100, according tovarious aspects of the present disclosure. In the depicted aspects, thecircuit 2000 includes a switch 2002, a first limit switch 2004 (e.g., anormally open switch), a second limit switch 2006 (e.g., a normallyclosed switch), a power source 2008, and a motor 2010 (e.g., a motorthat is configured to drive the first force/rotationtransmitting/converting assembly 240). The circuit 2000 can furtherinclude a first relay 2012 (e.g., a single-pole double-throw relay), asecond relay 2014 (e.g., a single-pole single-throw relay), a thirdrelay 2016 (e.g., a double-pole double-throw relay), a current sensor2018, and a current detection module 2030. In one aspect, the circuit2000 can include a motor control circuit 2028 that is configured tosense the electrical current through the motor 2010 and then control thecurrent accordingly. In the aspect depicted in FIG. 102, the secondrelay 2014, the current sensor 2018, the position sensor 2020, and thecurrent detection module 2030 collectively form the motor controlcircuit 2028. In the aspect depicted in FIG. 103, the second relay 2014,the current sensor 2018, the position sensor 2020, and the controller2034 collectively form the motor control circuit 2028. As describedbelow, the motor control circuit 2028 controls the current to the motor2010 by interrupting the current based upon the sensed current, thusdeactivating the motor 2010 when certain conditions occur.

The switch 2002 is activated when an operator of the surgical instrument100 initiates the firing of the clamping member 550 to clamp the endeffector 500 and cut and/or staple tissue. The first limit switch 2004is configured to remain open when the cutting/stapling operation of theend effector 500 is not yet complete. When the first limit switch 2004is open, the coil 2022 of first relay 2012 is de-energized, thus forminga conductive path between the power source 2008 and the second relay2014 via a normally-closed contact of the first relay 2012. The coil2026 of the second relay 2014 is controlled by the current detectionmodule 2030 and the position sensor 2020 as described below. When thecoil 2026 of the second relay 2014 and the coil 2022 of the first relay2012 are de-energized, a conductive path between the power source 2008and a normally-closed contact of the third relay 2016 is formed. Thethird relay 2016 controls the rotational direction of the motor 2010based on the states of switches 2004, 2006. When first limit switch 2004is open and the second limit switch 2006 is closed (indicating that theclamping member 550 has not yet fully deployed distally), the coil 2024of the third relay 2016 is de-energized. Accordingly, when coils 2022,2024, 2026 are collectively de-energized, current from the power source2008 flows through the motor 2010 via the normally-closed contacts ofthe third relay 2016 and causes the forward rotation of the motor 2010,which in turn causes the clamping member 550 to be driven distally bythe motor 2010 to clamp the end effector 500 and cut and/or stapletissue.

When the clamping member 550 has been fully advanced distally, the firstlimit switch 2004 is configured to close. When the first limit switch2004 is closed, the coil 2022 of the first relay 2012 is energized andthe coil 2024 of third relay 2016 is energized via a normally opencontact of the first relay 2012. Accordingly, current now flows to themotor 2010 via normally-open contacts of relays 2012, 2016, thus causingreverse rotation of the motor 2010 which in turn causes the clampingmember 550 to retract from its distal position and the first limitswitch 2004 to open. The second limit switch 2006 is configured to openwhen the clamping member 550 is fully retracted. The coil 2022 of thefirst relay 2012 remains energized until the second limit switch 2006 isopened, indicating the complete retraction of the clamping member 550.

The magnitude of current through the motor 2010 during its forwardrotation is indicative of forces exerted upon the clamping member 550 asit is driven distally by the motor 2010. If a staple cartridge 702 isnot loaded into the end effector 500, an incorrect staple cartridge 702is loaded into the end effector 500, or if the clamping member 550experiences unexpectedly high resistance from the tissue as it cutsand/or staples the tissue, the resistive force exerted against theclamping member 550 causes an increase in motor torque, which therebycauses the motor current to increase. If the motor current exceeds athreshold, the motor control circuit 2028 can cut off the electricalcurrent to the motor 2010, which deactivates the motor and causes theadvancement of the clamping member 550 to pause. Accordingly, by sensingthe current through the motor 2010, the motor control circuit 2028 candifferentiate between when the clamping member 550 is being advancedwithin or outside normal operational thresholds.

The current sensor 2018 may be coupled to a path of the circuit 2000that conducts current to the motor 2010 during its forward rotation. Thecurrent sensor 2018 may be any current sensing device (e.g., a shuntresistor, a Hall effect current transducer, etc.) suitable forgenerating a signal (e.g., a voltage signal) representative of sensedmotor current. The generated signal may be input to the currentdetection module 2030 for processing therein. According to the aspectdepicted in FIG. 102, the current detection module 2030 may beconfigured for comparing the signal generated by the current sensor 2018to a threshold signal (e.g., a threshold voltage signal) via acomparator circuit 2032 for receiving the threshold and current sensor2018 signals and generating a discrete output based on a comparison ofthe received signals. In some aspects, a value of the threshold signalmay be empirically determined a priori by measuring the peak signalgenerated by the current sensor 2018 when the clamping member 550 isinitially deployed (e.g., over an initial period or length of its distalmovement) during a cutting and stapling operation. In other aspects, thevalue of the threshold signal can be a pre-determined value that can, inone example, be retrieved from a memory.

In some aspects, it may be desirable to limit the comparison of thesensed motor current to the threshold value to a particular position orrange(s) of positions along the firing stroke of the clamping member550. In these aspects, the motor control circuit 2028 further includes aposition sensor 2020 that is configured to generate a signal indicativeof the position of the clamping member 550 (or alternatively, acomponent of the second or third force/rotation transmitting/convertingassemblies 250, 260 for aspects wherein the motor 2010 represented inFIGS. 102 and 103 drives the second or third force/rotationtransmitting/converting assemblies 250, 260). The position sensor 2020can include, for example, the position sensing assembly depicted in FIG.104 and described in fuller detail below. The position sensor 2020 isconnected in series with the comparator circuit 2032 (or themicrocontroller 2034 of the aspect depicted in FIG. 103) to limit thecomparison based on the position of the clamping member 550.Accordingly, if the signal generated by the current sensor 2018 exceedsthe threshold signal (indicating that unexpectedly high resistance isbeing encountered by the clamping member 550) and the clamping member550 is within a particular zone as determined by the position sensor2020, the coil 2026 of the second relay 2014 will be energized. Thiscauses normally-closed switch of the second relay 2014 to open, therebyinterrupting current flow to the motor 2010 and pausing the advancementof the clamping member 550. In this way, if the threshold signal isexceeded when the position of the clamping member 550 is not at aposition that activates the position sensor 2020, then the motor controlcircuit 2038 will not deactivate the motor 2010, regardless of theresult of the comparison. In other aspects, the motor control circuit2038 is configured to monitor the motor current along the entirety ofthe firing stroke of the clamping member 550. In these aspects, themotor control circuit 2038 lacks the position sensor 2020 (or theposition sensor 2020 is deactivated) and the output of the comparatorcircuit 2032 (or the microcontroller 2034) is fed directly to the secondrelay 2014. Accordingly, if the signal generated by the current sensor2018 exceeds the threshold signal at any point along the firing strokeof the clamping member 550, then current flow to the motor 2010 isinterrupted, in the manner described above.

According to the aspect depicted in FIG. 103, the motor control circuit2028 can include a processor-based microcontroller 2034 in lieu of thecurrent detection module 2030 described above. Although not shown forpurposes of clarity, the microcontroller 2034 may include componentswell known in the microcontroller art, such as a processor, a randomaccess memory (RAM) unit, an erasable programmable read-only memory(EPROM) unit, an interrupt controller unit, timer units,analog-to-digital conversion (ADC) and digital-to-analog conversion(DAC) units, and a number of general input/output (I/O) ports forreceiving and transmitting digital and analog signals. In on example,the microcontroller 2034 includes motor controllers comprising A3930/31Kmotor drivers from Allegro Microsystems, Inc. The A3930/31K motordrivers are designed to control a 3-phase brushless DC (BLDC) motor withN-channel external power MOSFETs, such as the motors 152, 154, 156 (FIG.4). Each of the motor controllers is coupled to a main controllerdisposed on the main controller circuit board 142 b (FIG. 4). The maincontroller is also coupled to memory, which is also disposed on the maincontroller circuit board 142 b (FIG. 4). In one example, the maincontroller comprises an ARM Cortex M4 processor from FreescaleSemiconductor, Inc. which includes 1024 kilobytes of internal flashmemory. The main controller communicates with the motor controllersthrough an FPGA, which provides control logic signals. The control logicof the motor controllers then outputs corresponding energization signalsto their respective motors 152, 154, 156 using fixed frequency pulsewidth modulation (PWM).

The current sensor 2018 and the position sensor 2020 may be connected toanalog and digital inputs, respectively, of the microcontroller 2034,and the coil 2026 of the second relay 2014 may be connected to a digitaloutput of the microcontroller 2034. It will be appreciated that inaspects in which the output of the position sensor 2020 is an analogsignal, the position sensor 2020 may be connected to an analog inputinstead. Additionally, although the circuit 2000 includes relays 2012,2014, 2016, it will be appreciated that in other aspects the relayswitching functionality may be replicated using solid state switchingdevices, software, and combinations thereof. In certain aspects, forexample, instructions stored and executed in the microcontroller 2034may be used to control solid state switched outputs of themicrocontroller 2034. In such aspects, switches 2004, 2006 may beconnected to digital inputs of the microcontroller 2034.

FIG. 104 illustrates a schematic diagram of a position sensor 2102 of asurgical instrument 100, according to one aspect of the presentdisclosure. The position sensor 2102 may be implemented as an AS5055EQFTsingle-chip magnetic rotary position sensor available from AustriaMicrosystems, AG. The position sensor 2102 is interfaced with thecontroller 2104 to provide an absolute positioning system 2100. Theposition sensor 2102 is a low-voltage and low-power component andincludes four Hall effect elements 2106A, 2106B, 2106C, 2106D in an area2120 of the position sensor 2102 that is located above a magnet that iscoupled to a component of the surgical instrument 100. The magnet can becoupled to, for example, a drive shaft of the motor driving the firstforce/rotation transmitting/converting assembly 240, the proximal driveshaft 212 of the first force/rotation transmitting/converting assembly240, or a gear assembly that is rotatably driven by the clamping member550 as the clamping member 550 is translated. In other words, the magnetcan be coupled to a component of the surgical instrument 100 such thatthe angular position of the magnet with respect to the Hall effectelements 2106A, 2106B, 2106C, 2106D corresponds to a longitudinalposition of, for example, the clamping member 550. A high-resolution ADC2108 and a smart power management controller 2112 are also provided onthe chip. A CORDIC processor 2110 (for Coordinate Rotation DigitalComputer), also known as the digit-by-digit method and Volder'salgorithm, is provided to implement a simple and efficient algorithm tocalculate hyperbolic and trigonometric functions that require onlyaddition, subtraction, bitshift, and table lookup operations. The angleposition, alarm bits, and magnetic field information are transmittedover a standard serial communication interface such as an SPI interface2114 to the controller 2104. The position sensor 2102 provides 12 or 14bits of resolution. The position sensor 2102 may be an AS5055 chipprovided in a small QFN 16-pin 4×4×0.85 mm package.

The Hall effect elements 2106A, 2106B, 2106C, 2106D are located directlyabove the rotating magnet (not shown). The Hall effect is a well-knowneffect and for expediency will not be described in detail herein;however, generally, the Hall effect produces a voltage difference (theHall voltage) across an electrical conductor transverse to an electriccurrent in the conductor and a magnetic field perpendicular to thecurrent. A Hall coefficient is defined as the ratio of the inducedelectric field to the product of the current density and the appliedmagnetic field. It is a characteristic of the material from which theconductor is made, since its value depends on the type, number, andproperties of the charge carriers that constitute the current. In theAS5055 position sensor 2102, the Hall effect elements 2106A, 2106B,2106C, 2106D are capable producing a voltage signal that is indicativeof the absolute position of the magnet 1202 in terms of the angle over asingle revolution of the magnet 1202. This value of the angle, which isunique position signal, is calculated by the CORDIC processor 2110 isstored onboard the AS5055 position sensor 2102 in a register or memory.The value of the angle that is indicative of the position of the magnet1202 over one revolution is provided to the controller 2104 in a varietyof techniques, for example, upon power up or upon request by thecontroller 2104.

The AS5055 position sensor 2102 requires only a few external componentsto operate when connected to the controller 2104. Six wires are neededfor a simple application using a single power supply: two wires forpower and four wires 2116 for the SPI interface 2114 with the controller2104. A seventh connection can be added in order to send an interrupt tothe controller 2104 to inform that a new valid angle can be read. Uponpower-up, the AS5055 position sensor 2102 performs a full power-upsequence including one angle measurement. The completion of this cycleis indicated as an INT output 2118, and the angle value is stored in aninternal register. Once this output is set, the AS5055 position sensor2102 suspends to sleep mode. The controller 2104 can respond to the INTrequest at the INT output 2118 by reading the angle value from theAS5055 position sensor 2102 over the SPI interface 2114. Once the anglevalue is read by the controller 2104, the INT output 2118 is clearedagain. Sending a “read angle” command by the SPI interface 2114 by thecontroller 2104 to the position sensor 2102 also automatically powers upthe chip and starts another angle measurement. As soon as the controller2104 has completed reading of the angle value, the INT output 2118 iscleared and a new result is stored in the angle register. The completionof the angle measurement is again indicated by setting the INT output2118 and a corresponding flag in the status register.

Due to the measurement principle of the AS5055 position sensor 2102,only a single angle measurement is performed in very short time (˜600μs) after each power-up sequence. As soon as the measurement of oneangle is completed, the AS5055 position sensor 2102 suspends topower-down state. An on-chip filtering of the angle value by digitalaveraging is not implemented, as this would require more than one anglemeasurement and, consequently, a longer power-up time that is notdesired in low-power applications. The angle jitter can be reduced byaveraging of several angle samples in the controller 2104. For example,an averaging of four samples reduces the jitter by 6 dB (50%).

FIG. 105 illustrates a logic flow diagram of a process 2200 formonitoring a motor current of a surgical instrument 100, according toone aspect of the present disclosure. In the following description ofthe process 2200, reference should also be made to FIGS. 102-104, whichdepict various sensor assemblies utilized by the process 2200, and FIGS.106-107, which depict various firing strokes of the clamping member 550executed according to the process 2200. The presently described process2200 can be executed by a controller, which includes the control circuitdepicted in FIGS. 102-103, the microcontroller 2104 of FIG. 104, oranother control circuit and/or processor that is executing logic and/orinstructions stored in a memory of the surgical instrument 100. Theprocess 2200 begins to be executed when the clamping andcutting/stapling operations of the end effector 500 are initiated 2202.

Accordingly, the process 2200 executed by the controller advances 2204the clamping member 550 from a first or proximal position by energizingthe motor 2010 to which the clamping member 550 is operably connected.The advancement of the clamping member 550 between a first or proximalposition and a second or distal position can be referred to as a strokeor a firing stroke. During the course of a full stroke of the clampingmember 550, the clamping member 550 will clamp the end effector 500 andthen cut and/or staple tissue held thereby. The stroke of the clampingmember 550 can be represented, for example, as a graph where the x-axiscorresponds to the distance or time over which the clamping member 550has advanced, as depicted in FIGS. 106-107. The actions effectuated bythe clamping member 550 can correspond to positions or zones definedwithin the stroke of the clamping member 550. For example, there can bea position in the stroke where the clamping member 550 has closed theend effector 500 and is thereafter cutting and/or stapling tissue. Asanother example, there can be a position in the stroke of the clampingmember 550 where the clamping member 550 is no longer ejecting staplesor cutting tissue. The controller can also take various actionsaccording to the position of the clamping member 550. For example, therecan be a position where the speed at which the clamping member 550 isdriven is controlled or changed by a controller. These positions orzones can refer to actual physical positions at which the clampingmember is located or relative positions within the stroke of theclamping member. The positions or zones can alternatively be representedas times in the stroke of the clamping member 550, as depicted in FIG.106.

As the clamping member 550 is advanced 2204, the controller detects 2206the motor current via, for example, the current sensor 2018. Thecontroller then determines 2208 whether the clamping member 550 is atthe closure end position. In one example, the controller can determine2208 whether the clamping member is at the closure end position via theposition sensor 2102. The closure end position corresponds to thelocation in the firing stroke of the clamping member 550 after theclamping member 550 has closed the end effector 500 and is thereaftercutting tissue and/or firing staples as the clamping member 550continues to advance distally. In some aspects, the controller canretrieve the closure end position from a memory and then compare thestored closure end position to the detected position of the clampingmember 550 to determine if the detected position matches or exceeds thestored closure end position. In other aspects, the controller candetermine the closure end position by, for example, monitoring for apeak in the motor current. If the clamping member 550 is not at theclosure end position, the process 2200 proceeds along the NO branch andthe controller continues causing the motor 2010 to advance 2204 theclamping member 550. The process 2200 continues this loop until theclamping member 550 is located at the closure end position.

If the controller determines 2208 that the clamping member 550 islocated at or beyond the closure end position, the process 2200 proceedsalong the YES branch and the controller selects 2210 the target firingspeed at which the clamping member 550 is to be driven by the motor 2010according to the value of the motor current at the closure end position.The level of motor current required to close the end effector 500 can beindicative of various properties of the clamped tissue. For example, thevalue of the motor current at the closure end position can correspond tothe thickness of the clamped tissue because the force exerted by theclamping member 550 to clamp tissue is proportional to the thickness ofthe tissue. As the force exerted by the clamping member 550 or thetorque exerted by the motor 2010 is proportional to the current drawn bythe motor 2010, the level of the motor current at the closure endposition thus corresponds to the thickness of the clamped tissue. It canbe desirable to set the target firing speed at which the clamping member550 is driven according to the thickness of the clamped tissue becauseadvancing the clamping member 550 too quickly through thick tissue cancause improper staple formation and increase the strain on the motor2010. As another example, the level of motor current can also correspondto the anatomical type of the clamped tissue (e.g., lung tissue,gastrointestinal tissue, or cardiac tissue) because the physicalresistance exerted on the cutting surface 554 driven by the clampingmember 550 can vary for different tissue types. In some aspects, thecontroller can compare the sensed value of the motor current at theclosure end position to a range of motor current values and thendetermine whether the sensed motor current has exceeded one or morethresholds or falls within one or more zones of the range. Thecontroller can then select 2210 the target firing speed for the clampingmember 550 as a particular value or set a tolerance threshold for thetarget firing speed including a range of values, which correspond towhere the sensed motor current lies within the range.

After selecting 2210 the target firing speed, the controller then causesthe clamping member 550 to advance 2212 at an initial speed. The initialspeed and the length of time or distance over which the clamping member550 is advanced at the initial speed can be set values that areretrieved by the controller from a memory or calculated values that aredetermined by the controller as a function of the tissue thickness. Insome aspects, the controller lacks this step of the process 2200 andinstead simply proceeds to advance the clamping member 550 at thedetermined target speed. The initial speed can be a value that is lessthan the target firing speed. In other words, the controller can causethe motor 2010 to initially advance the clamping member 550 at a lowerspeed in a first zone or portion of the firing strike relative to asubsequent portion or zone of the firing stroke. In some aspects, thevalue of the initial speed can be zero or nearly zero. It can bedesirable to advance 2212 the clamping member 550 at a lower speedinitially in order to allow the fluid to drain from the tissue clampedat the end effector 500. Fluid drains from clamped tissue due to themechanical forces exerted on the tissue by the end effector 500. In oneaspect, the length of time or distance that the clamping member 550 isadvanced at the initial speed can vary according to the thickness of theclamped tissue.

During the portion of the firing stroke of the clamping member 550directly following the closure end position, the controller furtherdetermines 2214 whether the motor current exceeds a maximum or lockoutthreshold. The controller can retrieve the lockout threshold from amemory. The sensed motor current exceeding the lockout thresholdindicates that the clamping member 550 is not being advanced distallyfrom the closure end position. The clamping member 550 can be preventedfrom advancing distally in the portion of its firing stroke immediatelyfollowing the closure end position for a variety of reasons, such as ifthe end effector 500 lacks a staple cartridge assembly 700. If the motorcurrent exceeds the lockout threshold, the process 2200 proceeds alongthe YES branch and stops 2216 in order to reduce strain on the motor2010. The controller can thereafter cause the surgical instrument 100 todisplay an alert to the operator or take other such actions.

If the motor current does not exceed the lockout threshold, the process2200 proceeds along the NO branch the controller then causes theclamping member 550 to advance 2218 at an increasing rate of speed untilthe speed reaches the target speed value or is within the target speedrange (which is a function of the tissue thickness). In some aspects,the rate at which the controller causes the motor 2010 to drive theclamping member 550 to increase the speed of the clamping member 550 isa set or predetermined rate. In other aspects, the rate at which thespeed of the clamping member 550 is increased is a function of one ormore parameters, such as the tissue thickness. In other words, thecontroller could be configured to cause the speed of the clamping member550 to increase more slowly for thicker tissue or increase more quicklyfor thinner tissue.

As the clamping member 550 is advanced distally (i.e., fired), thecontroller detects 2220 the motor current. The controller accordinglydetermines 2222 whether the sensed motor current exceeds a thresholdvalue. In one example, the threshold value can be retrieved by thecontroller from a memory for comparison to the detected 2220 motorcurrent. This threshold can be the same or different than the lockoutthreshold described above. Furthermore, the threshold can correspond tothe tissue thickness, for example. In some aspects, if the controllerdetermines 2222 that the motor current has exceeded the determinedthreshold, then the process 2200 proceeds along the YES branch and thecontroller decreases 2224 the firing speed of the clamping member 550.In other aspects, if the controller determines 2222 that the motorcurrent has exceeded the determined threshold, then the process 2200proceeds along the YES branch and the controller pauses 2224 theclamping member 550 at its current position in its firing stroke.Decreasing the firing speed of or pausing 2224 the clamping member 550reduces the torque experienced by the motor 2010 (to zero, in the caseof pausing the clamping member 550). After a particular length of timeor after the clamping member 550 had advanced a particular distance (inthe case where the clamping member 550 is slowed, not paused), theprocess 2200 loops back and the controller again causes the clampingmember 550 to advance 2218. The elapsed time or distance before whichthe controller begins causing the clamping member 550 to increase inspeed can be a set value or can be a function of a tissue parameter(e.g., the tissue thickness).

If the controller determines 2222 that the clamping member 550 has notexceeded a threshold, the process 2200 proceeds along the NO branch andthe controller then determines 2226 whether the clamping member 550 islocated at the firing end position. The firing end position correspondsto the distal point reached by the clamping member 550 in its firingstroke to cut tissue and/or fire staples from the end effector 500. Ifthe clamping member 550 has not reached the firing end position, theprocess 2200 proceeds along the NO branch and loops back. The controllerthen continues to advance 2218 the clamping member 550 (and increase itsspeed, as appropriate) and detects 2220 the motor current during thecourse of the firing stroke to determine 2222 whether the motor currentexceeds the threshold. The controller continues this loop until itdetermines 2226 that the clamping member 550 is located at the firingend position. If the controller determines 2226 that the clamping member550 is located at the firing end position, the process 2200 proceedsalong the YES branch and then stops 2228.

To provide further explanation regarding the function(s) described abovethat the controller is configured to execute, the process 2200 will bediscussed in terms of several example firing strokes depicted in FIGS.106-107. FIG. 106 illustrates a first graph 2300 and a second graph2302, each of which depict a first firing stroke 2304 and a secondfiring stroke 2306 of the clamping member 550. The first graph 2300depicts motor current 2303 versus time 2301 and the second graph 2302depicts clamping member speed 2305 versus time 2301 for the examplefiring strokes 2304, 2306 of the clamping member 550. The time 2301 axisis delineated into a “CLOSURE” zone, a “CUTTING/STAPLING” zone, and a“STOP” zone, which indicates the action(s) that the clamping member 550is effectuating in each respective portion of its firing stroke. Incombination, the first graph 2300 and the second graph 2302 illustratethe relationship between motor current 2303 and clamping member speed2305 for different firing strokes 2304, 2306 and the resulting actionstaken by a controller executing the process 2200 depicted in FIG. 105.

As discussed above in connection with FIG. 105, the controller executingthe process 2200 can be configured to select 2210 the firing speed atwhich the clamping member 550 is to be driven according to the motorcurrent at the closure end position 2308. In other words, the controlleris configured to select 2210 a firing speed of the clamping member 550that is appropriate for or that otherwise corresponds to the thicknessof the clamped tissue, as indicated by the motor current at the closureend position 2308. In one aspect, the controller selects the firingspeed of the clamping member 550 according to where the sensed motorcurrent at the closure end position 2308 falls within a range of values.In some aspects, this can be expressed as whether the motor current atthe closure end position 2308 has surpassed one or more thresholds in arange of motor current values. In other aspects, this can be expressedas whether the motor current at the closure end position 2308 fallswithin a particular zone or zones in a range of motor current values.

In the depicted aspect, there are a first threshold T₁, a secondthreshold T₂, and a third threshold T₃, which can demarcate zonescorresponding to thin tissue, medium tissue, and thick tissue,respectively. In other words, if the motor current at the closure endposition 2308 is below T₁, then the tissue can be considered to be thinbecause relatively little torque was exerted by the motor 2010 to clampthe end effector 500 on the tissue. Accordingly, if the motor current atthe closure end position 2308 has exceeded T₁, but is below T₂, then thetissue can be considered to be of medium, normal, or expected thickness.Accordingly, if the motor current at the closure end position 2308 hasexceeded T₂, but is below T₃, then the tissue can be considered to thickbecause the motor 2010 was required to exert a high degree of torque toclamp the tissue. If the motor current at the closure end position 2308exceed T₃, then the tissue can be considered to be too thick to cut andstaple or may have been clamped improperly. In that case, the process2200 can display a warning to the operator and/or lockout the surgicalinstrument 100 from advancing the clamping member 550 further. Thedepiction of three thresholds T₁, T₂, T₃ is simply illustrative and theprocess 2200 can incorporate any number of thresholds, however. Thespeed at which the clamping member 550 is to be driven can be selectedby the process 2200 executed by the controller to correspond to therelative tissue thickness, which is indicated by the motor current atthe closure end position 2308. In the depicted aspect, there are a firstspeed zone S₁ that is selected if the motor current does not exceed T₁,a second speed zone S₂ that is selected if the motor current fallsbetween T₁ and T₂, and a third speed zone S₃ that is selected if themotor current falls between T₂ and T₃. The first speed zone S₁ to thethird speed zone S₃ correspond to increasingly slower speeds. It can bedesirable to drive the clamping member 550 at a faster rate throughthinner tissue because thin tissue provides little resistance to properstaple formation and thus the operation can be completed more quicklywithout sacrificing staple quality. Conversely, it can be desirable todrive the clamping member 550 at a slower rate through thicker tissuebecause staples may not be formed properly in thicker tissue if the sled712 (FIG. 10) is driven too quickly by the clamping member 550. Drivingthe sled 712 at a slower rate thus ensures that the staples fully piercethe tissue and are fully formed against the anvil plate 620 (FIG. 10).

The first firing stroke 2304 and the second firing stroke 2306 areexamples where the controller determines 2222 that the motor currentexceeds a threshold during the course of the clamping member firingstroke and then pauses 2224 the clamping member 550. For example, in thefirst firing stroke 2304 the closure motor current 2312 at the closureend position 2308 has exceed the second threshold T₂; therefore, thecontroller selects the slowest speed zone S₃ as the target speed atwhich the clamping member 550 is to be driven during thecutting/stapling phase of the firing stroke. In the second firing stroke2306 the closure motor current 2319 at the closure end position 2308 hasexceed the first threshold T₁; therefore, the controller selects themedium speed zone S₂ as the target speed at which the clamping member550 is to be driven during the cutting/stapling phase of the firingstroke. The speed zones S₁, S₂, S₃ set the upper and lower tolerancethresholds for the speed at which the clamping member 550 is driven bythe motor 2010. If the speed of the clamping member 550 exceeds theupper and lower limits of the speed zone S₁, S₂, S₃ selected by thecontroller, then the controller can be configured to take variousactions, such as controlling the motor 2010 to increase or decrease thespeed at which the clamping member 550 is driven or adjusting theelectrical energy supplied to the motor 2010. In other words, the speedzones S₁, S₂, S₃ represent ranges of acceptable speeds in which thespeed at which the clamping member 550 is actually translated can varywithout causing the controller to take corrective action. It should beappreciated that although the target speed zones S₁, S₂, S₃ are depictedas ranges in the second graph 2302, they could alternatively be discretevalues. In general, it can be desirable to set tolerance ranges for thespeed at which the clamping member 550 is advancing because the speedwill naturally vary during a firing stroke because tissue is not uniformin thickness, the clamping member 550 tends to slow as the sled 712ejects staples (which are spaced from each other), and the tissuecutting surface 554 (FIG. 10) may be advancing through different typesof tissue with different physical properties.

Continuing the description of the first firing stroke 2304, after theclosure end position 2308 the controller causes the speed at which theclamping member 550 is advanced to drop from the closure speed 2332 toan initial speed 2333, which may be lower than the selected target speed(and in some cases is zero). The initial speed 2333 corresponds to a lowinitial motor current 2313. The controller then gradually increases thespeed at which the clamping member 550 is driven to a target speed 2334that is within the target speed range S₃ previously selected by thecontroller. As the clamping member speed increases, the motor currentlikewise increases 2314. If the clamping member 550 does not encounterany abnormal resistance from the tissue as the tissue cutting surface554 is driven therethrough, the clamping member speed will thus bemaintained within the target speed range S₃ through the firing strokeuntil the stop position 2310. However, in this example, the speedinstead begins decreasing thereafter. As the speed decreases, the motorcurrent increases until it peaks 2315 and reaches the maximum thresholdT₃. The clamping member speed dropping while the motor current issimultaneously increasing indicates that the tissue cutting surface 554driven by the clamping member 550 is encountering thicker than expectedtissue or there is otherwise an error that is causing the torque on themotor 2010 to increase unexpectedly. When unexpectedly thick tissue isencountered, the torque on the motor 2010 can increase while theclamping member speed is, at best, maintained or, in this case, falls.When the motor current meets or exceeds the maximum threshold T₃ (atpeak 2315), the controller reduces or cuts 2316 the current to the motor2010, which cause the clamping member speed to drop 2335 to a lowerspeed or, in some aspects, to zero (i.e., the clamping member 550 ispaused). After a period of time, the controller re-energizes the motor2010 and gradually increases 2317 the motor current in order to causethe speed at which the clamping member 550 is driven to graduallyincrease to a target speed 2336 within the target speed range S₃. Aslong as the motor current does not re-exceed the maximum threshold T₃,the clamping member 550 continues to advance until it reaches the stopposition 2310. At that point, the controller causes the motor current todrop 2318 to zero and the clamping member speed likewise drops 2337 tozero as the clamping member slows to a stop due to the motor 2010 beingde-energized.

A similar series of events described above with respect to the firstfiring stroke 2304 occurs with respect to the second firing stroke 2306,except that the controller selects the target speed range as S₂ becausethe closure motor current 2319 only exceeded the first threshold T₁ atthe closure end position 2308. As with the first firing stroke 2304,after the closure end position 2308 the controller causes the speed atwhich the clamping member 550 is advanced to drop from the closure speed2326 to an initial speed 2327. The controller then gradually increasesthe speed at which the clamping member 550 is driven to a target speed2328 that is within the target speed range S₂ previously selected by thecontroller. As the clamping member speed increases, the motor currentlikewise increases 2321. As with the first firing stroke 3406, the speedbegins decreasing and the motor current increases until it peaks 2322and reaches the maximum threshold T₃. As the motor current meets orexceeds the maximum threshold T₃ (at peak 2322), the controller reducesor cuts 2323 the current to the motor 2010, which cause the clampingmember speed to drop 2329 to a lower speed or, in some aspects, to zero(i.e., the clamping member 550 is paused). After a period of time, thecontroller re-energizes the motor 2010 and gradually increases 2324 themotor current to increase the clamping member speed a target speed 2330within the target speed range S₂. The time delay prior to the controllerre-energizing the motor can vary for different conditions encounteredduring the firing stroke. As can be noted from either the first graph2300 or the second graph 2302, the length of time that the current iscut 2316 in the first firing stroke 2304 is greater than the length oftime that the current is cut 2323 in the second firing stroke 2306. Insome aspects, the length of the pause (or the length of time at whichthe clamping member 550 is driven at a lower or initial speed) can be afunction of the tissue thickness. For example, the controller can pausethe advancement of the clamping member 550 longer for thicker tissue.The controller continues to advance the clamping member 550 until itreaches the stop position 2338. At that point, the controller causes themotor current to drop 2325 to zero and the clamping member speedlikewise drops 2331 to zero as the clamping member slows to a stop dueto the motor 2010 being de-energized. As can further be noted, the stopposition 2338, 2310 can vary. In some aspects, the location of the stopposition 2338, 2310 can vary according to the length of the cartridgebody 702 present into the end effector 500. In other aspects, thelocation of the stop position 2338, 2310 can be set by the operator ofthe surgical instrument 100 to a shorter (i.e., more proximal) positionthan the maximum stop position.

FIG. 107 illustrates a third graph 2400 and a fourth graph 2402, each ofwhich depict a third firing stroke 2404, a fourth firing stroke 2406,and a fifth firing stroke 2408 of the clamping member 550. The thirdgraph 2400 depicts motor current 2403 versus clamping memberdisplacement distance 2401 and the fourth graph 2402 depicts clampingmember speed 2405 versus displacement distance 2401 for the examplefiring strokes 2404, 2406, 2408 of the clamping member 550. Thedisplacement distance 2401 axis is delineated into a “CLOSURE” zone, a“CUTTING/STAPLING” zone, and a “STOP” zone, which indicates theaction(s) that the clamping member 550 is driving in each respectiveportion of its firing stroke. In combination, the third graph 2400 andthe fourth graph 2402 illustrate the relationship between motor current2403 and clamping member speed 2405 for different firing strokes 2404,2406, 2408 and the resulting actions taken by a controller executing theprocess 2200 depicted in FIG. 105.

As discussed above in connection with FIG. 105, the controller executingthe process 2200 can be configured to select 2210 the firing speed atwhich the clamping member 550 is to be driven according to the motorcurrent at the closure end position 2410. In other words, the controlleris configured to select 2210 a firing speed for the clamping member 550that is appropriate for or that otherwise corresponds to the thicknessof the clamped tissue, as indicated by the motor current at the closureend position 2410. In one aspect, the controller selects the firingspeed of the clamping member 550 according to where the sensed motorcurrent at the closure end position 2410 falls within a range of values.In some aspects, this can be expressed as whether the motor current atthe closure end position 2410 has surpassed one or more thresholds in arange of motor current values. In other aspects, this can be expressedas whether the motor current at the closure end position 2410 fallswithin a particular zone or zones in a range of motor current values. Inthe depicted aspect, the motor current 2403 includes a first zone i₁ asecond zone i₂, and a third zone i₃. The zones may or may not becontiguous with each other. The depiction of three zones i₁, i₂, i₃along the axis of the motor current 2403 is simply illustrative and theprocess 2200 can incorporate any number of thresholds, however.

As also discussed above in connection with FIG. 105, the process 2200executed by the controller can be configured to determine 2214 whetherthe motor current exceeds a lockout threshold 2415. The third firingstroke 2404 represents an example firing stroke wherein the controllerdetermines 2214 that the lockout threshold 2415 is exceeded. In thethird firing stroke 2404, the motor current spikes 2414 in the portionof the firing stroke immediately following the closure end position2410, reaching or exceeding the lockout threshold 2415, as the clampingmember speed sharply drops 2416 to zero. In other words, the motorcurrent increases sharply with minimal or no corresponding movement ofthe clamping member 550. When the motor current reaches the lockoutthreshold 2415, the process 2200 executed by the controller stops 2216and the controller can display a warning to the operator and/or lockoutthe surgical instrument 100 from firing the clamping member 550. In oneexample, the spike 2414 in the motor current exhibited by the thirdfiring stroke 2404 directly after the closure end position 2410 can beindicative of a cartridge 702 not being present or being improperlyloaded in the end effector 500.

The fourth firing stroke 2406 is an example where controller determines2222 that the motor current exceeds a threshold during the course of theclamping member stroke and then decreases 2224 the speed of the clampingmember 550. In the fourth firing stroke 2406, the closure motor current2418 falls within the i₂ zone; therefore, the controller selects S₂ asthe target speed range 2436. After the closure end position 2410, thecontroller causes the clamping member speed to decrease from the closurespeed 2432 to an initial speed 2434. The controller then causes thedisplacement member speed to increase from the initial speed 2434 to atarget speed 2436 in the selected speed range S₂. It should be notedthat the initial speed 2434 can be a set value or a range of values. Themotor current correspondingly increases 2420 as the displacement memberspeed increases. As the clamping member 550 continues advancing in thefourth firing stroke 2406, the clamping member 550 hits a point wherethe motor current sharply increases 2422 such that it exceeds athreshold demarcated by the upper boundary of the i₂ zone. The sharpincrease 2422 in the motor current is indicative of the cutting surface554 being driven through an unexpectedly thick portion of the clampedtissue. In this example, there are multiple thresholds (demarcated bythe boundaries of the current zones i₁, i₂, i₃) that the controllercompares the sensed motor current against to determine 2222 whether todecrease 2224 the displacement member speed or pause the clamping member550. This is in contrast to the first firing stroke 2304 and the secondfiring stroke 2306 where the controller only took action (i.e., pausedthe clamping member 550 in the particular examples) when the motorcurrent reached or exceeded a singular maximum threshold (T₃). When themotor current exceeds the threshold, the controller decreases 2438 theclamping member speed from the original speed range S₂ to the lowerspeed range S₃. The controller then causes the motor 2010 to advance theclamping member 550 at the lower speed 2440. As the clamping member 550advances at the lower speed range S₃, the motor current continues 2424in the higher current range i₃ until it sharply decreases 2426 past thelower boundary of the i₃ current zone. The sharp decrease 2426 in themotor current is indicative of the cutting surface 554 being driventhrough a thinner portion of the clamped tissue because less current isrequired to advance the clamping member 550 at the target speed. Whenthe motor current reaches or exceeds the threshold represented by thislower boundary, the controller then causes the motor 2010 to increase2442 the clamping member speed from the lower speed range S₃ back to theoriginal speed range S₂. Through the remaining portion of the fourthfiring stroke 2406, the displacement member speed continues 2444 withinthe target speed range S₂ (with the motor current likewise continuing2428 with its respective range i₂) until the clamping member 550 reachesthe firing end position 2412. When the clamping member 550 reaches thefiring end position 2412, the controller cuts 2430 the motor current andthe clamping member speed correspondingly drops 2446 to zero as themotor 2010 is de-energized.

The fifth firing stroke 2408 represents a firing stroke wherein theclamping member 550 is driven through clamped tissue lacking anysignificant variations in thickness. In the fifth firing stroke 2408,the closure motor current 2448 falls within the i₁ zone; therefore, thecontroller selects S₁ as the target speed range 2458. After the closureend position 2410, the controller causes the clamping member speed todecrease from the closure speed 2454 to an initial speed 2456. Thecontroller then causes the displacement member speed to increase fromthe initial speed 2456 to a target speed 2458 in the selected speedrange S₃. In the present example, the clamping member 550 maintains itsspeed within the target speed 2458 for the entire length of the firingstroke. The motor current is likewise maintained 2450 within theboundaries of the current zone i₁. In other words, the clamping member550 does not encounter any portions of tissue that is appreciablythicker or thinner relative to the expected tissue thickness (i.e., thetissue thickness indicated by the closure motor current 2418) as theclamping member 550 advances from the closure end position 2410 to thefiring end position 2412. When the clamping member 550 reaches thefiring end position 2412, the controller cuts 2452 the motor current,which causes the clamping member speed to drop 2460 to zero as the motor2010 is de-energized.

FIG. 108 illustrates a diagram of an end effector 10000 including a gapsensor 10006 and a cartridge identity sensor 10010, according to oneaspect of the present disclosure. The gap sensor 10006 is configured tosense the gap or distance between the first jaw member 10004 (i.e., theanvil assembly 610) and the second jaw member 10006 (i.e., the cartridgeassembly 700) by sensing the relative position of a magnet 10008. Theposition sensor 10006 can include a Hall effect sensor, among othersensors configured to detect the relative distance between components.In one aspect depicted in FIG. 109, the position sensor 10006 comprisesa Hall element 10100, an amplifier 10102, and a power source 10104. TheHall element comprises a first input terminal 10108A and a second inputterminal 10108B. The first and second input terminals 10108A, 10108B areconfigured to receive a constant input current from the power source10104. When no magnetic field is present, the input current enters thefirst input terminal 10108A and exits the second input terminal 10108Bwith no loss of voltage potential to either side of the Hall element10100. As a magnetic field is applied to the Hall element 10100, suchas, for example, by magnet 10008, a voltage potential is formed at thesides of the Hall element 10100 due to the deflection of electronsflowing through the Hall element 10100. A first output terminal 10108Cand a second output terminal 10108D are located at opposite sides of theHall element 10100. The first and second output terminals 10108C, 10108Dprovide the voltage potential caused by the magnetic field to theamplifier 10102. The amplifier 10102 amplifies the voltage potentialexperienced by the Hall element 10100 and outputs the amplified voltageto an output terminal 10106. Therefore, the output of the positionsensor 10006 corresponds to the relative distance of the magnet 10008 tothe Hall element 10100. Detecting the distance between the jaw members10006, 10008 can be beneficial because this distance corresponds to thethickness of the grasped tissue when the end effector 10000 is clamped.Therefore, sensing the distance between the jaw member 10006, 10008 canbe used in lieu of, or in addition to, determining the tissue thicknessfrom the motor current to clamp the end effector 10000, as describedabove.

Referring back to FIG. 108, the cartridge identity sensor 10010 isconfigured to sense the type or identity of a cartridge 702 present inthe end effector 10000. In one aspect where the end effector 10000 is aMULU with replaceable cartridges 702, the cartridge identity sensor10010 includes a receiver that is configured to receive a signal (e.g.,a RF signal) transmitted from the cartridge 702. In another aspect wherethe end effector 10000 is a MULU, the cartridge identity sensor 10010includes an electrical contact that is configured to contact acorresponding electrical contact of the cartridge 702 when the cartridge702 is inserted into the end effector 10000. Upon the cartridge 702being inserted, the cartridge 702 transmits a signal through theelectrically connected electrical contacts, which is received by acontroller of the surgical instrument 100 to identity the cartridge 702.

In another aspect where the end effector 10000 is a SULU, the cartridgeidentity sensor 10010 is configured to detect when the end effector10000 is mated to the adapter 200. In this aspect depicted in FIGS.110-111, the terminal end 10206 of the adapter 200 includes one or moreelectrical contacts 10200, which each include a bent portion 10202. Theend effector 500 further includes a memory disposed within or on the endeffector housing 10201. The memory includes a memory chip and one ormore electrical contacts 10204 electrically connected to the memorychip. The memory chip is configured to store one or more parametersrelating to the end effector 500. The parameters can include a serialnumber of the end effector 500, a type of the end effector 500 and/orthe cartridge 702 therein, a size of end effector 500 and/or thecartridge 702 therein, a staple size, information identifying whetherthe end effector 500 has been fired, a length of the end effector 500and/or the cartridge 702 therein, maximum number of uses of the endeffector 500, and combinations thereof. When the end effector 500 ismated to the adapter 200, the end effector electrical contacts 10204engaged the adapter electrical contacts 10200. The memory chip isconfigured to communicate the presence of the end effector 500 and oneor more of the parameters of the end effector 500 described herein, viaelectrical contacts 10200,100204, upon engagement of the end effector500 with the adapter 200.

FIG. 112 illustrates a logic flow diagram of a process 10300 forselecting an initial speed at which to fire the clamping member 550,according to one aspect of the present disclosure. In the followingdescription of the process 10300, reference should also be made to FIGS.108-111, which depict various sensor assemblies utilized by the process10300, and FIG. 113, which depicts various firing strokes of theclamping member 550 executed according to the process 10300. Thepresently described process 10300 can be executed by a controller, whichincludes the control circuit depicted in FIGS. 102-103, themicrocontroller 2104 of FIG. 104, or another control circuit and/orprocessor that is executing logic and/or instructions stored in a memoryof the surgical instrument 100. The process 10300 begins to be executedwhen the clamping and cutting/stapling operations of the end effector500 are initiated 10302.

Accordingly, the process 10300 executed by the controller first advances10304 the clamping member 550 by energizing the motor 2010 to which theclamping member 550 is operably connected. The controller thendetermines 10306 whether the clamping member 550 is at the closure endposition. In one example, the controller can determine 10306 whether theclamping member 550 is at the closure end position via the positionsensor 2102 (FIG. 104). The closure end position corresponds to thelocation in the firing stroke of the clamping member 550 after theclamping member 550 has closed the end effector 500 and is thereaftercutting tissue and/or firing staples. In some aspects, the controllercan retrieve the closure end position from a memory and then compare theknown closure end position to the sensed position of the clamping member550. In other aspects, the controller can determine the closure endposition by monitoring for a peak in the motor current. If the clampingmember 550 is not at the closure end position, the process 10300proceeds along the NO branch and the controller continues causing themotor 2010 to advance 10304 the clamping member 550. The process 2200continues this loop until the clamping member 550 is located at orbeyond the closure end position.

If the controller determines 10306 that the clamping member 550 islocated at or beyond the closure end position in its firing stroke, theprocess 10300 proceeds along the YES branch and then determines 10308the gap distance between the anvil assembly 610 and the cartridgeassembly 700. In one example, the controller determines 10308 the gapdistance via the gap sensor 10006. The controller then determines 10310the type or identity of the cartridge 702 and/or the end effector 500.In one example, the controller determines 10310 the type or identity ofthe cartridge 702 via the cartridge identity sensor 10100. The cartridgethen determines 10312 whether the gap distance is acceptable for thesensed cartridge type. Different types of cartridges 702 have differentacceptable tolerance ranges; therefore, a gap distance between the anvilassembly 610 and the cartridge assembly 700 that is suitable (i.e.,within operational tolerances) for one type of cartridge 702 may not besuitable for another type of cartridge 702. If the controller determinesthat the gap distance is not suitable for the given cartridge type, theprocess 10300 proceeds along the NO branch and stops 10314. In thatcase, the process 10300 can display a warning to the operator and/orlockout the surgical instrument 100 from firing the clamping member 550.

If the controller determines that the gap distance is suitable for thegiven cartridge type, the process 10300 proceeds along the YES branchand next determines 10316 the target firing speed for the clampingmember 550 according to the sensed gap distance and the sensed cartridgetype. In one aspect, the controller can select a target firing speedaccording to whether the sensed gap distance exceeds one or morethresholds or falls within one or more zones within a range of gapdistances that are particular to a given cartridge type. In other words,different cartridge types may have different tolerance ranges for thespeeds at which the clamping member 550 can be advanced for differentthicknesses of the clamped tissue. Across cartridge types, thecontroller can be configured to generally select slower firing speedsfor thicker tissue and faster firing speeds for thinner tissue; however,whether a given thickness of tissue is considered to be relatively thickor relatively thin will vary according to the cartridge type. Afterdetermining 10316 the appropriate target firing speed, the process 10300stops 10318.

To provide further explanation regarding the function(s) described abovethat the controller is configured to execute, the process 10300 will bediscussed in terms of several example firing strokes depicted in FIG.113. FIG. 113 illustrates a graph 10400 that depicts several firingstrokes 10406, 10408, 10410, 10412, 10414, 10416, 10418 of the clampingmember 550 corresponding to different cartridge types. In the graph10400, the first firing stroke 10406, the second firing stroke 10408,the fifth firing stroke 10414, and the seventh firing stroke 10418correspond to a first cartridge type; the third firing stroke 10410 andthe sixth firing stroke 10416 correspond to a second cartridge type; andthe fourth firing stroke 10412 corresponds to a third cartridge type.The graph 10400 depicts the gap distance 10404 of the end effector 500versus the displacement distance 10402 of the clamping member 550. Theresulting actions taken by a controller executing the process 10300(i.e., determining 10316 the firing speed) depends upon gap distance10404 at the closure end position 10420 for the cartridge type of eachfiring stroke. The graph 10400 also depicts a variety of thresholds x₁ .. . x₆ along the gap distance 10404 axis that delineate zonestherebetween. The sequentially increasing thresholds x₁ . . . x₆ cancorrespond to increasingly larger values of the gap distance 10404. Eachcartridge type does not necessarily utilize all of the depictedthresholds x₁ . . . x₆ and different cartridge types can use the same ordifferent thresholds x₁ . . . x₆ and/or zones, as will be discussedbelow. Furthermore, although six thresholds x₁ . . . x₆ are depicted,the process 10300 executed by the controller can utilize any number ofthresholds and/or zones in practice.

For the first cartridge type, the thresholds x₆, x₅, and x₃ define thezones that determine the firing speed selected by the controller. Forexample, at the closure end position 10420 the first firing stroke 10406is located at a position 10407 exceeding x₆. Exceeding the x₆ thresholdcorresponds to the clamped tissue being too thick to cut and staple forthe given cartridge type or having been clamped improperly. In thiscase, the controller can display a warning to the operator and/orlockout the surgical instrument 100 from firing the clamping member 550.The second firing stroke 10408 is located at a position 10409 in a zonebetween x₆ and x₅ at the closure end position 10420, which correspondsto a large gap or thick tissue for the given cartridge type. Therefore,the controller can select a slower firing speed for the clamping member550. The fifth firing stroke 10414 is located at a position 10415 in azone between x₅ and x₃ at the closure end position 10420, whichcorresponds to a medium gap or medium, normal, or expected tissuethickness for the given cartridge type. Therefore, the controller canselect a medium or normal firing speed for the clamping member 550. Theseventh firing stroke 10418 is located at a position 10419 in a zonebelow x₃ at the closure end position 10420, which corresponds to a smallgap or thin tissue for the given cartridge type. Therefore, thecontroller can select a fast firing speed for the clamping member 550.

The relevant thresholds can vary for different cartridge types. For thesecond cartridge type, the x₄ threshold delineates zones defining a fastfiring speed and a normal firing speed. For example, the third firingstroke 10410 is located at a position 10411 in a zone above x₄ at theclosure end position 10420, which corresponds to a medium gap or amedium, normal, or expected tissue thickness for the given cartridgetype. Therefore, the controller can select a medium or normal firingspeed for the clamping member 550. The sixth firing stroke 10416 islocated at a position 10417 in a zone below x₄ at the closure endposition 10420, which corresponds to a small gap or thin tissue for thegiven cartridge type. Therefore, the controller can select a fast firingspeed for the clamping member 550.

The relevant thresholds can also be shared between different cartridgetypes. For the third cartridge type, the x₄ threshold delineates zonesdefining a fast firing speed and a normal firing speed (as with thesecond cartridge type of the third firing stroke 10410 and the sixthfiring stroke 10416). For example, the fourth firing stroke 10412 islocated at a position 10413 in a zone below x₄ at the closure endposition 10420, which corresponds to a small gap or thin tissue for thegiven cartridge type. Therefore, the controller will select a fastfiring speed for the clamping member 550.

In sum, the process 10300 executed by the controller can select theappropriate firing speed for the clamping member 550 during thecutting/stapling portion of its firing stroke according to where thesensed gap distance between the anvil assembly 610 and the cartridgeassembly 700 falls relative to various tolerance ranges, which may beunique to each cartridge type. The process 10300 thus allows thecontroller to customize the speed at which the clamping member 550 isfired to cut and/or staple tissue according to the thickness of theclamped tissue and the cartridge type.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

FIG. 114 illustrates a logic flow diagram of a process 15000 forcontrolling a speed of a clamping member 550 during a firing stroke,according to one aspect of the present disclosure. In the followingdescription of the process 15000, reference should also be made to FIGS.102-104, which depict various sensor assemblies utilized by the process15000, and FIG. 116, which depicts various firing strokes of theclamping member 550 executed according to the process 15000. Thepresently described process 15000 can be executed by a controller, whichincludes the control circuit depicted in FIGS. 102-103, themicrocontroller 2104 of FIG. 104, or another control circuit and/orprocessor that is executing logic and/or instructions stored in a memoryof the surgical instrument 100. The process 15000 begins to be executedwhen the clamping and cutting/stapling operations of the end effector500 are initiated 15002.

Accordingly, the process 15000 executed by the controller advances 15004the clamping member 550 from a first or proximal position by energizingthe motor 2010 to which the clamping member 550 is operably connected.The advancement of the clamping member 550 between a first or proximalposition and a second or distal position can be referred to as a strokeor a firing stroke. During the course of a full stroke of the clampingmember 550, the clamping member 550 will clamp the end effector 500 andthen cut and/or staple tissue held thereby. The stroke of the clampingmember 550 can be represented, for example, as a graph where the x-axiscorresponds to the distance or time over which the clamping member 550has advanced, as depicted in FIG. 116. The actions effectuated by theclamping member 550 can correspond to positions or zones defined withinthe stroke of the clamping member 550. For example, there can be aposition in the stroke where the clamping member 550 has closed the endeffector 500 and is thereafter cutting and/or stapling tissue. Asanother example, there can be a position in the stroke of the clampingmember 550 where the clamping member 550 is no longer ejecting staplesor cutting tissue. The controller can also take various actionsaccording to the position of the clamping member 550. For example, therecan be a position where the speed at which the clamping member 550 isdriven is controlled or changed by a controller. These positions orzones can refer to actual physical positions at which the clampingmember is located or relative positions within the stroke of theclamping member. The positions or zones can alternatively be representedas times in the stroke of the clamping member 550.

As the clamping member 550 is advanced 15004, the controller determines15006 whether the clamping member 550 is at or near (i.e., within atolerance of) a defined position in the firing stroke of the clampingmember 550. A defined position is a pre-defined location in the firingstroke of the clamping member 550 where the controller is configured toincrease the clamping member speed (i.e., step up the motor 2010) ordecrease the clamping member speed (i.e., step down the motor 2010).There can be zero, one, or multiple defined positions in the process15000 executed by the controller. The defined positions can be locatedat or near the proximal or distal ends of the firing stroke or can belocated at any intermediate position therebetween. In some aspects, theclosure end position and the firing end position are defined positionswherein the controller can be configured, for example, to slow the speedat which the clamping member 550 is being driven by the motor 2010. Theclosure end position corresponds to the location in the firing stroke ofthe clamping member 550 after the clamping member 550 has closed the endeffector 500 and is thereafter cutting tissue and/or firing staples. Inone example, slowing the clamping member 550 as it approaches theclosure end position can be useful in order to prevent the clampingmember 550 from inadvertently colliding with a lockout stop when thereis no staple cartridge present in the end effector 500. The firing endposition corresponds to the distal point reached by the clamping member550 in its firing stroke to cut tissue and/or fire staples from the endeffector 500. In one example, slowing the clamping member 550 as itapproaches the firing end position can be useful in order to prevent theclamping member 550 from inadvertently colliding with the distal end ofthe anvil elongated slot 622. In yet another aspect, the firing strokeof the clamping member 550 includes an intermediate defined positionpositioned between the closure end position and the firing end positionwhere the controller is configured to drive the clamping member 550 at afaster speed.

In some aspects, the controller determines 15006 whether the clampingmember 550 is approaching or located at a defined position by detectingthe present position of the clamping member 550 (e.g., via the positionsensor 2102), retrieving one or more stored positions from a memory, andthen comparing the detected position to the one or more stored positionsto determine if the detected position matches or is within a tolerancedistance from at least one of the stored positions. In other aspects,the controller determines 15006 whether the clamping member 550 isapproaching or located at a defined position by sensing the motorcurrent and determining whether the sensed motor current or the rate ofchange of the sensed motor current has exceeded a particular threshold(as described below in FIG. 115). If the controller determines 15006that the clamping member 550 is not located at a defined position, theprocess 15000 proceeds along the NO branch and loops back to continueadvancing 15004 the clamping member 550.

If the controller determines 15006 that the clamping member 550 islocated at (or within a tolerance of) a defined position, the process15000 proceeds along the YES branch and then changes 15008 the clampingmember speed in the manner dictated by the particular defined position.When the controller determines 15006 that the clamping member 550 islocated at or near a defined position, the controller can retrieve themanner in which the clamping member speed is to be changed (e.g.,whether the speed is to be increased or decreased, a particular value orspeed range to which the speed is to be set, or a function forcalculating a value or speed range to which the speed is to be set) froma memory that stores each how the clamping member speed is to be changedin association with each of the stored positions. The controller thencontrols the motor 2010 to increase or decrease the speed at which theclamping member 550 is driven accordingly.

The controller then determines 15010 whether the clamping member 550 islocated at a stop position. The controller can determine 15010 thelocation of the clamping member 550 in the same manner described above,namely via a position sensor 2102 or sensing the motor current relativeto one or more thresholds. If the clamping member 550 is located at thestop position, then the process 15000 proceeds along the YES branch andstops 15012. When the process 15000 executed by the controller stops15012, the controller can take various actions, such as cutting thecurrent to the motor 2010 or displaying a notification to the user thatthe clamping member 550 has stopped. If the clamping member 550 is notlocated at the stop position, then the process 15000 proceeds along theNO branch and continues to advance 15004 the clamping member 552. Thisloop continues until the clamping member 550 reaches the stop positionand the process 15000 stops 15012.

FIG. 115 illustrates a logic flow diagram of a process 15100 fordetecting a defined position according to motor current, according toone aspect of the present disclosure. In the following description ofthe process 15100, reference should also be made to FIGS. 102-104, whichdepict various sensor assemblies utilized by the process 15100, and FIG.116, which depicts various firing strokes of the clamping member 550executed according to the process 15100. The presently described process15100 can be executed by a controller, which includes the controlcircuit depicted in FIGS. 102-103, the microcontroller 2104 of FIG. 104,or another control circuit and/or processor that is executing logicand/or instructions stored in a memory of the surgical instrument 100.The process 15100 begins to be executed when the cutting/staplingoperation of the end effector 500 is initiated 15102.

As the controller controls the motor 2010 to advance 15104 the clampingmember 550, the controller monitors or detects 15106 the motor current(e.g., via the current sensor 2018). Further, the controller determines15108 whether the detected motor current or the rate of change of thedetected motor current is greater than or equal to a particularthreshold value that is indicative of the firing end position in thestroke of the clamping member 550. In other words, the controllerdetermines 15108 whether the motor current spikes or peaks above acertain level, either by comparing the value of the motor current or therate of change of the motor current to a particular threshold. Becausethe motor current tends to sharply increase above a particular thresholdas the clamping member 550 approaches certain positions, such as theclosure end position and the firing end position, the controller can beconfigured to monitor the motor current for an indicative increase inthe motor current and then take action to slow the clamping member 550or otherwise prevent the clamping member 550 as it approaches thesepositions. Slowing the clamping member 550 in this manner can preventthe clamping member 550 from sharply contacting the distal ends of theanvil assembly 610 and/or cartridge assembly 700. In some aspects, thecontroller can be configured to cross-reference the detected motorcurrent with a position detected from a position sensor 2102 to confirmthat the clamping member 550 is located at or near a position where itwould be expected for the motor current to increase or decrease in themanner that is being detected. If the controller determines 15108 thatthe motor current has not exceeded the threshold, the process 15100proceeds along the NO branch and continues advancing 15104 the clampingmember 550. If the controller determines 15108 that the motor currenthas exceed the end of stroke threshold, the process 15100 proceeds alongthe YES branch and the process 15100 stops 15110. In some aspects, whenthe process 15100 stops 15110 the controller de-energizes the motor2010.

To provide further explanation regarding the function(s) described abovethat the controller is configured to execute, the processes 15000, 15100will be discussed in terms of several example firing strokes depicted inFIG. 116. FIG. 116 illustrates a first graph 15200 and a second graph15202, each of which depict a first firing stroke 15204, a second firingstroke 15206, and a third firing stroke 15208 of the clamping member 550between an initial or proximal position 15216 and an end or distalposition 15218. The first graph 15200 depicts motor current 15203 versusclamping member displacement distance 15201 and the second graph 2302depicts clamping member speed 15205 versus clamping member displacementdistance 15201 for the example firing strokes 15204, 15206, 15206 of theclamping member 550. The displacement distance 15201 axis is delineatedinto a “CLOSURE” zone, a “CUTTING/STAPLING” zone, and a “STOP” zone,which indicates the action(s) that the clamping member 550 iseffectuating in each respective portion of its firing stroke. Incombination, the first graph 15200 and the second graph 15202 illustratethe relationship between motor current 15203 and clamping member speed15205 for different firing strokes 15204, 15206, 15208 and the resultingactions taken by a controller executing the processes 15000, 15100depicted in FIGS. 114-115.

For each of the firing strokes 15204, 15206, 15208, as the displacementmember 550 advances from the initial position 15216 to the closure endposition 15210 the motor current sharply increases 15220, 15222, 15224.In one example, the controller executing the process 15000 depicted inFIG. 114 can detect this sharp increase 15220, 15222, 15224 in the motorcurrent by sensing when the rate of change in the motor current for eachof the firing strokes 15204, 15206, 15208 exceeds a threshold, asdepicted in FIG. 116. The process 15000 then decreases 15226, 15228,15230 the speed of the clamping member 550 accordingly as it reaches theclosure end position 15210. As the clamping member 550 advances past theclosure end position 15210, the controller increases 15232, 15234, 15236the speed at which the clamping member 550 is driven until the clampingmember 550 is driven within a particular speed range S₁, S₂, S₃. In oneexample, the controller increases 15232, 15234, 15236 the speed at whichthe clamping member 550 is driven until the clamping member 550 isdriven within a speed range S₁, S₂, S₃ corresponding to the thickness ofthe tissue clamped at the end effector 500.

In some aspects, such with the second and third firing strokes 15206,15208, the clamping member 550 is thereafter driven at a consistentspeed or within a consistent speed range. In other aspects, such as withthe first firing stroke 15204, the controller is configured to controlthe motor 2010 to drive the clamping member 550 at varying speeds toaccount for varying tissue properties. For example, in the first firingstroke 15204 the motor current increases 15238 as the clamping member550 approaches an intermediate position 15214, potentially due to thecutting surface 554 of the clamping member 550 encountering increasinglythick tissue. In response, the controller can be configured to decrease15252 the speed at which the clamping member 550 is driven in order toprevent the motor current from continuing to increase. Decreasing 15252the clamping member speed reduces the current drawn by the motor 2010because it lowers the torque on the motor 2010. In some aspects, thecontroller can be configured to change the maximum acceptable current ortorque limits on the motor 2010 in response to detected conditions. Forexample, in the first firing stroke 15204 the first or initial maximumacceptable current limit of the motor 2010 is delineated by the upperbound of the current range i₂ that was selected by the controller inaccordance with the clamped tissue thickness. However, when the motorcurrent 15238 increases as the clamping member 550 approaches theintermediate position 15214, the controller can be configured toupwardly adjust the maximum motor current to a second maximum acceptablecurrent limit delineated by the upper bound of the current range i₃.

As the clamping member 550 approaches the firing end position 15212 themotor current sharply increases 15240, 15242, 15244 for each of thefiring strokes 15204, 15206, 15208 until it reaches a threshold 15215.The controller executing the process 15000 depicted in FIG. 114 candetect that the motor current has reached or surpassed this threshold15215, which is indicative of the clamping member 550 approaching thefiring end position 15212. The process 15000 then decreases 15246,15248, 15250 the speed of the clamping member 550 accordingly in each ofthe firing strokes 15204, 15206, 15208 and the clamping member 550 slowsas it reaches the stop position 15218 (i.e., the distal most position ofits firing stroke). When the clamping member 550 reaches the stopposition 15218, the processes 15000, 15100 can stop and the controllercan take various actions, such as displaying an alert to the operator ofthe surgical instrument 100 indicating that the clamping, cutting,and/or stapling by the surgical instrument 100 has been completed.

In some aspects, the surgical instrument 100 includes stops that areconfigured to prevent the clamping member 550 (or another component ofthe firing drive system) from becoming damaged by inadvertentlycolliding with the anvil assembly 610 and/or the cartridge assembly 700at the end of its firing stroke. The stops can be constructed frommaterials that are deformable, bendable, or configured to strainelastically in order to absorb or attenuate the forces from the clampingmember 550 as it is advanced to the terminal position of its firingstroke. The stops can be utilized in combination with, or in lieu of, acontroller executing a process, such as the process 15100 depicted inFIG. 115, to detect the firing stroke end position and then slow and/orstop the clamping member 550 accordingly.

FIGS. 117-120 illustrate various views of a stop member 15300 that isengaged with the elongated slot 15352 of the anvil plate 15350. In thedepicted aspect, the stop member 15300 includes a vertical stem or body15302, a base 15304 extending orthogonally from the body 15302, and oneor more flanges 15306 a, 15306 b. The base 15304 extends across thesurface 15364 of the anvil plate 15350. The flanges 15306 a, 15306 bbear against the interior surface of the shelf 15356 of the elongatedslot 15352 and the base 15304 bears against the surface 15364, whichsecures the stop member 15300 within the elongated slot 15352 and thusprevents the stop member 15300 from being withdrawn therefrom. The stopmember 15300 can be positioned at or adjacently to the distal end 15354of the elongated slot 15352 and serve as a physical obstruction orbarrier preventing the clamping member 15358 from colliding with thedistal end 15354 during the stroke of the clamping member 15358 as ittranslates from a first or proximal position 15360 to a second or distalposition 15362.

FIGS. 121-122 illustrate longitudinal sectional views of an end effector15454 and a drive assembly including a stop member 15400. In one aspect,the surgical instrument 100 includes one or more projections 15450extending from the shaft assembly 203 (FIG. 1) or the end effector15454. In the depicted aspect, the projections 15450 extend outwardlyfrom the proximal portion of the end effector 15454, adjacent to thepivot joint 15452. The drive beam 15402 includes one or more stopmembers 15400 extending generally orthogonally therefrom that areconfigured to contact the projections 15450. The stop members 15400 arerigidly connected to the drive beam 15402 such that the drive beam 15402is prevented from being advanced further distally when the stop members15400 contact the projections 15450. The stop members 15400 arepositioned on the drive beam 15402 such that the clamping member 15404does not contact the distal end 15458 of the elongated slot 15456 whenthe stop members 15400 contact the projections 15450. Stateddifferently, the distance from the distal end 15458 of the elongatedslot 15456 to the projections 15450 is larger than the distance betweenthe distal end of the clamping member 15404 and the stop members 15400.The projections 15450 and/or the stop members 15400 can be constructedfrom deformable materials or materials that are configured to strainelastically.

FIGS. 123-124 illustrate longitudinal sectional views of an end effector15454 including a stop member 15500 located distally in the elongatedslot 15456. In the depicted aspect, the end effector 15454 includes astop member 15500 located at the distal end 15458 of the elongated slot.In this aspect, the stop member 15500 is located within or occupies thedistal end 15458 or the distal end 15458 terminates at the stop member15500. In either case, the stop member 15500 is positioned such that theclamping member 15404 is configured to contact it when the clampingmember 15404 has advanced to the most distal position in its firingstroke. The stop member 15500 can be constructed from deformablematerials or materials that are configured to strain elastically.

Referring back to FIG. 21, the adapter 200 can include a lockingmechanism 280 that is configured to fix the axial or longitudinalposition of the distal drive member 248. In some cases, it may bedesirable for the lock mechanism 280 to control a switch or transmit asignal to the controller to indicate that the lock mechanism 280 isengaged and thus that the motor 2010 should not be activated to attemptto drive the distal drive member 248. In one aspect, the adapter 200include a switch (not shown) that is tripped when the camming member 288of the locking mechanism 280 cams into the recess 249 of the distaldrive member 248. The switch is communicably coupled to the controllerof the surgical instrument 100. If the controller determines that thelocking mechanism switch has indicated that the locking mechanism 280 isengaged, then the controller can limit or cut current to the motor 2010in order to prevent the motor 2010 from attempting to drive the lockeddistal drive member 248. Likewise, when the camming member 288 iswithdrawn from the recess 249 of the distal drive member 248, then theswitch can be un-tripped or re-tripped to indicate to the controllerthat the locking mechanism 280 has been disengaged and that the motor2010 can thus be energized to drive the distal drive member 248. Such anarrangement can be useful in order to, for example, prevent damage tothe motor 2010 and/or locking mechanism 280.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

What is claimed is:
 1. A method of operating a surgical end effectorincluding first and second jaws pivotally coupled together that areselectively movable between a fully open position and fully closedposition, said method comprising: moving a dynamic clamping assemblyconfigured to slidably contact the first and second jaws in a firstaxial direction through a closure stroke, wherein the dynamic clampingassembly applies a closure motion to the first and second jaws to movethe first and second jaws from the fully open position to the closedposition; further moving the dynamic clamping assembly in said firstaxial direction through a firing stroke, wherein the dynamic clampingassembly performs a surgical function until the dynamic clampingassembly reaches an ending position within the closed first and secondjaws; moving the dynamic clamping assembly in a second axial directionthat is opposite to the first axial direction from the ending position;and contacting at least one positive jaw opening feature on at least oneof the first and second jaws with the dynamic clamping assembly as thedynamic clamping assembly is moving in the second axial direction tomove the first and second jaws to the fully open position.
 2. The methodof claim 1, wherein said contacting comprises contacting a positive jawopening feature on each of the first and second jaws with the dynamicclamping assembly as the dynamic clamping assembly is moving in thesecond axial direction to move the first and second jaws to the fullyopen position.
 3. The method of claim 2, wherein said contactingcomprises: contacting a positive jaw opening feature on one of the firstand second jaws with the dynamic clamping assembly as the dynamicclamping assembly is moving in the second axial direction to apply aninitial jaw opening motion thereto; and contacting another positive jawopening feature on the other the first and second jaws with the dynamicclamping assembly as the dynamic clamping assembly is moving in thesecond axial direction to apply a final jaw opening motion thereto. 4.The method of claim 1, wherein each of the positive jaw opening featurescomprises an angled cam surface configured to be engaged by acorresponding portion of the dynamic clamping assembly and wherein saidcontacting comprises axially moving the dynamic clamping assembly in thesecond axial direction to cause the portion of the dynamic clampingassembly to cammingly engage the angled cam surface to apply a pivotingmotion to the one of the first and second jaws to which the positive jawopening feature is located on.
 5. The method of claim 1, wherein thefirst jaw comprises an anvil and the second jaw comprises a cartridgeassembly with fasteners stored therein and wherein said further movingthe dynamic clamping assembly in said first axial direction through afiring stroke comprises further moving the dynamic clamping assembly insaid first axial direction through the firing stroke such that thedynamic clamping assembly causes the fasteners stored in the cartridgeassembly to be ejected therefrom into forming contact with the anvil. 6.The method of claim 1, wherein said moving a dynamic clamping assemblyconfigured to slidably contact the first and second jaws in a firstaxial direction through a closure stroke, comprises: slidably contactinga proximal end portion of the first jaw with a first jaw contactingfeature on the dynamic clamping assembly; and cammingly contacting a camclosure feature on the second jaw with a second jaw contacting featureon the dynamic clamping assembly.
 7. The method of claim 1, furthercomprising positioning tissue between the first and second jaws when thefirst and second jaws are in the open position prior to said moving thedynamic clamping assembly through the closure stroke to cause the tissueto be clamped between the first and second jaws.
 8. The method of claim7, wherein the first jaw comprises an anvil and the second jaw comprisesa cartridge assembly with fasteners stored therein and wherein saidfurther moving the dynamic clamping assembly in said first axialdirection through a firing stroke comprises further moving the dynamicclamping assembly in said first axial direction through the firingstroke such that the dynamic clamping assembly causes the fastenersstored in the cartridge assembly to be ejected therefrom through theclamped tissue into forming contact with the anvil.
 9. The method ofclaim 8, wherein the dynamic clamping assembly includes a tissue cuttingsurface such that when the dynamic clamping assembly is moved in saidfirst axial direction through the firing stroke, the dynamic clampingassembly cuts the tissue that is clamped between the first and secondjaws.
 10. A method of operating an electromechanical surgical system,comprising: attaching an adapter to an electromechanical surgicalinstrument, the adapter comprising: an elongate shaft assemblyconfigured for operable attachment to the electromechanical surgicalinstrument; and a surgical end effector, comprising: a first jawincluding a first jaw distal end and a first jaw proximal end, whereinsaid first jaw proximal end is operably coupled to the shaft assembly; asecond jaw including a second jaw distal end and a second jaw proximalend, wherein said second jaw proximal end is pivotally coupled to saidfirst jaw such that said first jaw and said second jaw are movablerelative to each other between a fully open position and a closedposition; and a dynamic clamping assembly configured to apply openingand closing motions to said first and second jaws as said dynamicclamping assembly is axially driven between a starting position and anending position in response to firing motions generated by theelectromechanical surgical instrument and wherein said method furthercomprises: moving the dynamic clamping assembly in a first axialdirection through a closure stroke, wherein the dynamic clampingassembly applies a closure motion to the first and second jaws to movethe first and second jaws from the fully open position to the closedposition; further moving the dynamic clamping assembly in said firstaxial direction through a firing stroke, wherein the dynamic clampingassembly performs a surgical function until the dynamic clampingassembly reaches an ending position within the closed first and secondjaws; moving the dynamic clamping assembly in a second axial directionthat is opposite to the first axial direction from the ending position;and contacting at least one positive jaw opening feature on at least oneof the first and second jaws with the dynamic clamping assembly as thedynamic clamping assembly is moving in the second axial direction tomove the first and second jaws to the fully open position.
 11. Themethod of claim 10, wherein said contacting comprises contacting apositive jaw opening feature on each of the first and second jaws withthe dynamic clamping assembly as the dynamic clamping assembly is movingin the second axial direction to move the first and second jaws to thefully open position.
 12. The method of claim 10, wherein said contactingcomprises: contacting a positive jaw opening feature on one of the firstand second jaws with the dynamic clamping assembly as the dynamicclamping assembly is moving in the second axial direction to apply aninitial jaw opening motion thereto; and contacting another positive jawopening feature on the other the first and second jaws with the dynamicclamping assembly as the dynamic clamping assembly is moving in thesecond axial direction to apply a final jaw opening motion thereto. 13.The method of claim 10, wherein each of the positive jaw openingfeatures comprises an angled cam surface configured to be engaged by acorresponding portion of the dynamic clamping assembly and wherein saidcontacting comprises axially moving the dynamic clamping assembly in thesecond axial direction to cause the portion of the dynamic clampingassembly to cammingly engage the angled cam surface to apply a pivotingmotion to the one of the first and second jaws to which the positive jawopening feature is located on.
 14. The method of claim 10, wherein thefirst jaw comprises an anvil and the second jaw comprises a cartridgeassembly with fasteners stored therein and wherein said further movingthe dynamic clamping assembly in said first axial direction through afiring stroke comprises further moving the dynamic clamping assembly insaid first axial direction through the firing stroke such that thedynamic clamping assembly causes the fasteners stored in the cartridgeassembly to be ejected therefrom into forming contact with the anvil.15. The method of claim 10, wherein said moving a dynamic clampingassembly configured to slidably contact the first and second jaws in afirst axial direction through a closure stroke, comprises: slidablycontacting a proximal end portion of the first jaw with a first jawcontacting feature on the dynamic clamping assembly; and camminglycontacting a cam closure feature on the second jaw with a second jawcontacting feature on the dynamic clamping assembly.
 16. The method ofclaim 10, further comprising positioning tissue between the first andsecond jaws when the first and second jaws are in the open positionprior to said moving the dynamic clamping assembly through the closurestroke to cause the tissue to be clamped between the first and secondjaws.
 17. The method of claim 16, wherein the first jaw comprises ananvil and the second jaw comprises a cartridge assembly with fastenersstored therein and wherein said further moving the dynamic clampingassembly in said first axial direction through a firing stroke comprisesfurther moving the dynamic clamping assembly in said first axialdirection through the firing stroke such that the dynamic clampingassembly causes the fasteners stored in the cartridge assembly to beejected therefrom through the clamped tissue into forming contact withthe anvil.
 18. The method of claim 17, wherein the dynamic clampingassembly includes a tissue cutting surface such that when the dynamicclamping assembly is moved in said first axial direction through thefiring stroke, the dynamic clamping assembly cuts the tissue that isclamped between the first and second jaws.
 19. The method of claim 16,wherein said position comprises rotating the surgical end effector abouta longitudinal axis defined by the shaft assembly to position the firstand second jaws adjacent the tissue.
 20. The method of claim 16, whereinthe surgical end effector is configured to be selectively articulatedabout an articulation axis that is transverse to a longitudinal axisdefined by the shaft assembly upon application thereto of anarticulation motion from the electromechanical surgical instrument andwherein said positioning comprises articulating the surgical endeffector to an articulated position adjacent the tissue.